WORK NOTICES AND PRECAUTIONS NOTICE FOR HYBRID SYSTEM

PRECAUTIONS FOR HIGH-VOLTAGE CIRCUIT INSPECTION AND SERVICE
CAUTION:

This vehicle has a hybrid system that operates at voltages up to 650 V. The hybrid system uses an HV battery that contains an electrolyte which is a strong alkali solution that includes 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. Technicians must undergo special training to be able to service and inspect the high-voltage system.
2. All high-voltage wire harnesses and connectors are colored orange. The HV battery and other high-voltage components have "High Voltage" caution labels. Do not carelessly touch these wires or components.
3. When there is a problem with a wire harness or connector of a high-voltage circuit, repairs to the harness or connector should not be attempted. Replace damaged or malfunctioning high-voltage wire or connector.
4. Before inspecting or servicing the high-voltage system, be sure to follow all safety measures, such as wearing insulated gloves and removing the service plug grip to prevent electrocution. Carry the removed service plug grip in your pocket to prevent other technicians from accidentally reconnecting it while you are servicing the vehicle.
  
  Note
  
  After removing the service plug grip, do not turn the power switch on (READY), unless instructed by the repair manual, as this may cause a malfunction.
5. After removing the service plug grip, wait 10 minutes before touching any of the high-voltage connectors and terminals.
  
  Tech Tips
  
  Waiting for at least 10 minutes is required to discharge the high-voltage capacitor inside the inverter with converter assembly.
6. Before using insulated gloves, be sure to check them for cracks, tears and other types of damage by performing the following procedure.
  1. Place the glove on its side.
  2. Roll the opening up 2 or 3 times.
  3. Fold the opening in half to close it.
  4. Confirm that there are no air leaks.
7. When servicing the vehicle, do not carry metal objects like mechanical pencils or rulers that can be dropped accidentally and cause a short circuit.
8. Before touching a bare high-voltage terminal, wear insulated gloves and use a tester to make sure that the terminal voltage is 0 V.
9. After disconnecting or exposing a high-voltage connector or terminal, insulate it immediately using insulating tape.
10. Bolts and nuts for high-voltage terminals should be tightened to the specified torque. Both insufficient and excessive torque can cause a malfunction.
11. Use the "CAUTION: HIGH VOLTAGE DO NOT TOUCH" sign to notify other technicians that the high-voltage system is being inspected and/or repaired.
  
  *1 When performing work on the HV system, fold this sign and put it on the roof of the vehicle.
12. After servicing the high-voltage system and before reinstalling the service plug grip, check again that you have not left any parts or tools inside, that the high-voltage terminals are firmly tightened, and that the connectors are correctly connected.
13. When performing work involving a high-voltage circuit, use either a tool wrapped with vinyl insulation tape or an insulated tool.
14. When installing hybrid system components such as the HV battery, make sure that the polarity of all connections is correct.

*1	When performing work on the HV system, fold this sign and put it on the roof of the vehicle.

ACTIONS TO BE TAKEN FOR VEHICLES DAMAGED BY IMPACT

CAUTION:

This vehicle has a hybrid system that operates at voltages up to 650 V. The hybrid system uses an HV battery that contains an electrolyte which is a strong alkali solution that includes 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.

Items to be prepared for the accident site
- Protective clothing (insulated gloves, rubber gloves, goggles and safety shoes)
- 20 liters (21.1 US qts, 17.6 Imp. qts) saturated boric acid solution (obtain 800 g (1.76 lb) of boric acid powder, put it into a container, and dissolve it in water)
- Red litmus paper
- ABC fire extinguisher (effective against both oil flames and electrical flames)
- A shop rag or piece of cloth (for wiping up the neutralized electrolyte)
- Insulating tape (for insulating cables)
- Electrical tester

Actions to be taken at the accident site

CAUTION:

Do not touch any bare cables that could be high-voltage cables. If a cable must be touched or if accidental contact is possible, wear insulated gloves and insulate the cable using insulating tape.
If the vehicle catches on fire, use an ABC fire extinguisher to extinguish the fire. Trying to extinguish a fire using only a small amount of water can be more dangerous than effective. Use a substantial amount of water or wait for firefighters.
Visually check the HV battery and the surrounding area for any electrolyte leakage. Do not touch any leaked liquid because it could be highly alkaline electrolyte.
If the vehicle is submerged in water, work on the vehicle only after the vehicle has been pulled out of the water.

Check the vicinity of the HV battery for any leakage of the electrolyte.
CAUTION:
- Do not touch any leaked liquid because it could be highly alkaline electrolyte. Wearing rubber gloves and goggles, neutralize the liquid with saturated boric acid solution and then apply red litmus paper to the liquid. Check that the paper does not turn blue. Wipe up the neutralized electrolyte with a shop rag or piece of cloth.
- If the electrolyte comes in contact with your skin, use a saturated boric acid solution or a large amount of water to wash it off. If the electrolyte comes in contact with an article of clothing, take it off immediately.
- If the electrolyte comes in contact with your eyes, call out loudly for help. Do not rub your eyes. Wash them immediately with a large amount of water and seek medical care.

If damage to any of the high-voltage components and cables is suspected, cut the high-voltage circuit using the following procedure.

CAUTION:

Be sure to wear insulated gloves, goggles and safety shoes.

*A	w/o Rear No. 2 Seat	*B	w/ Rear No. 2 Seat
*1	COMPRESSOR WITH MOTOR ASSEMBLY	*2	INVERTER WITH CONVERTER ASSEMBLY
*3	HYBRID VEHICLE TRANSAXLE ASSEMBLY	*4	ENGINE ROOM RELAY BLOCK AND JUNCTION BLOCK ASSEMBLY
*5	HV FLOOR UNDER WIRE	*6	HV BATTERY
*7	REAR TRACTION MOTOR WITH TRANSAXLE ASSEMBLY	*8	AUXILIARY BATTERY

*1	Engine Room Relay Block And Junction Block Assembly
*2	IG2-MAIN Fuse

Turn the power switch off.

Tech Tips

If the power switch cannot be turned off, remove the IG2-MAIN fuse from the engine room relay block and junction block assembly. Then confirm that the READY light is not illuminated.

Disconnect the cable from the negative (-) auxiliary battery terminal.
While wearing insulated gloves, remove the service plug grip.

Note

After removing the service plug grip, do not turn the power switch on (READY), unless instructed by the repair manual because this may cause a malfunction.

Moving the damaged vehicle

Note

When towing the vehicle, refer to Precautions for Towing Electrical AWD Vehicles.

If any of the following conditions are met, tow the vehicle away using a tow truck.
- One or more of the high-voltage components and cables are damaged.
- Components related to driving, the hybrid transaxle, or the fuel system are damaged.
- The master warning light is on.
- The READY light does not come on when attempting to turn the power switch on (READY).
CAUTION:

Before towing the vehicle away using a tow truck, disconnect the cable from the negative (-) auxiliary battery terminal and remove the service plug grip.

Note

Perform the procedure below if the master warning light turns on, or there are abnormal noises, unusual smells, or strong vibrations while driving:
1. Park the vehicle in a safe place.
2. Apply the parking brake, and then move the shift lever to P.
3. Turn the power switch off, and disconnect the cable from the negative (-) auxiliary battery terminal.
4. While wearing insulated gloves remove the service plug grip.
Actions required after moving the damaged vehicle
1. Procedure
  
  If you see any liquid on the road surface, it could be highly alkaline electrolyte.
  
  Wearing rubber gloves and goggles, neutralize the electrolyte with saturated boric acid solution, and then apply red litmus paper to the liquid. Check that the paper does not turn blue. Wipe up the neutralized liquid with a shop rag or piece of cloth.
Items to be prepared (when repairing a damaged vehicle)
- Protective clothing (insulated gloves, rubber gloves, goggles and safety shoes)
- 20 liters (21.1 US qts, 17.6 Imp. qts) saturated boric acid solution (obtain 800 g (1.76 lb) of boric acid powder, put it into a container, and dissolve it in water)
- Red litmus paper
- A shop rag or piece of cloth (for wiping up the neutralized electrolyte)
- Insulating tape (for insulating cables)
- Electrical tester

Precautions to be observed when servicing a damaged vehicle

CAUTION:

Always follow instructions to ensure safety.

Wear insulated or rubber gloves, goggles, and safety shoes.
Check the HV battery and immediate area for any electrolyte leakage.
CAUTION:
- Do not touch any leaked liquid because it could be highly alkaline electrolyte. Wearing rubber gloves and goggles, neutralize the liquid with saturated boric acid solution and then apply red litmus paper to the liquid. Check that the paper does not turn blue. Wipe up the neutralized electrolyte with a shop rag or piece of cloth.
- If the electrolyte comes in contact with your skin, use a saturated boric acid solution or a large amount of water to wash it off. If the electrolyte comes in contact with an article of clothing, take it off immediately.
- If the electrolyte comes in contact with your eyes, call out loudly for help. Do not rub your eyes. Wash them immediately with a large amount of water and seek medical care.
Do not touch any bare cables that could be high-voltage cables. If a cable must be touched or if accidental contact is possible, follow the following instructions: 1) wear insulated gloves and goggles, 2) measure the voltage between the cable and body ground using an electrical tester, and 3) insulate the cable using insulating tape.
If damage to any of the high-voltage components and cables is suspected, cut the high-voltage circuit using the procedure below.

CAUTION:

Do not touch any bare cables that could be high-voltage cables. If a cable must be touched or if accidental contact is possible, wear insulated gloves and insulate the cable using insulating tape.

*1	Engine Room Relay Block And Junction Block Assembly
*2	IG2-MAIN Fuse

Turn the power switch off.

Tech Tips

If the power switch cannot be turned off, remove the IG2-MAIN fuse from the engine room relay block and junction block assembly. Then confirm that the READY light is not illuminated.

Disconnect the cable from the negative (-) auxiliary battery terminal.
While wearing insulated gloves, remove the service plug grip.

Note

After removing the service plug grip, do not turn the power switch on (READY), unless instructed by the repair manual because this may cause a malfunction.

Precautions to be taken when disposing of an HV battery
1. When disposing of an HV battery, make sure to return it through an authorized collection agent who is capable of handling it safely. If the HV battery is returned via the manufacturer specified route, it will be returned properly and in a safe manner by an authorized collection agent.
  CAUTION:
  - Accidents such as electric shock may result if the HV battery is disposed of improperly or abandoned. Therefore, make sure to return all HV batteries through an authorized collection agent.
  - After removing the HV battery, keep it away from water. Exposure to water may cause the HV battery to produce heat, resulting in a fire.
Precautions to be observed when towing
1. Tow the damaged vehicle with its front and rear wheels lifted off the ground.
  
  CAUTION:
  
  Towing the damaged vehicle with its wheels on the ground will cause the motor to generate electricity. This electricity could, depending on the nature of the damage, leak and cause a fire.
Towing with all 4 wheels on the ground
CAUTION:
- If the vehicle needs to be towed using a cable or chain with all 4 wheels on the ground, do not exceed 5 km/h (3 mph) and tow only for a short distance and then have the vehicle towed by a truck.
- Make sure to turn the power switch on (IG), and move the shift lever to N.
- Do not turn off the power switch. Turning off the power switch may result in engagement of the steering lock, resulting in a hazardous situation or accident.
- If any abnormality in the damaged vehicle is present occurs during towing, stop towing immediately.

PRECAUTIONS FOR TOWING ELECTRICAL 4WD VEHICLES
1. Use one of the following methods to tow the vehicle.
2. If the vehicle has trouble with the chassis or drivetrain, use method 1 (flatbed truck).
  Note
  
  Do not use any towing method other than those shown above.
  
  *1: If the vehicle is tilted after parking on a level surface, the braking force may be insufficient as the electric parking brake determines how much braking force to apply by automatically detecting the slope of the road.
  Tech Tips
  
  *2: When the electric parking brake switch (integration control and panel assembly) is pulled 2 times (2 application operations), the system uses the maximum amount of braking force.
3. If a tow truck is not available, in an emergency the vehicle may be temporarily towed using a cable or chain secured to the emergency towing eyelet(s). This should only be attempted on hard surfaced roads for as short of a distance as possible and at a vehicle speed of 5 km/h (3 mph) or less.
  
  A driver must be in the vehicle to steer and operate the brakes. The vehicle's wheels, drivetrain, axles, steering and brakes must be in good condition.
  
  Note
  
  If the towing speed exceeds the above limits, or if the vehicle is towed for a long distance or in a backward direction with any of the wheels on the ground, the drivetrain may be damaged.
  1. Emergency towing procedure
    1. Turn the power switch on (IG).
    2. Depress the brake pedal and move the shift lever to N.
    3. Release the parking brake.
    4. Release the brake pedal slowly.
    Note
    
    Use extreme caution when towing the vehicle. Avoid sudden starts or erratic driving maneuvers which place excessive stress on the emergency towing eyelet and the cables or chains.
    
    If the hybrid system is off, the power assist for the brakes and steering will not function, making steering and braking more difficult.
    
    Do not turn off the power switch. Turning off the power switch may result in engagement of the steering lock, resulting in a hazardous situation or accident.
4. The towing methods shown below are dangerous and can damage the vehicle, so do not use them.
  1. Do not tow the vehicle with only 2 wheels on the ground.
    
    Note
    
    If the vehicle is towed with only 2 wheels on the ground, the drivetrain may overheat and be damaged, or the wheels may come off the dollies.
  2. Do not use a sling-type towing method either from the front or rear.
    
    Note
    
    If a sling-type tow truck is used, damage may occur to the vehicle body.