IMA Technical Information and Emergency Handling Guide

IMA Technical Information and Emergency Handling Guide

Preface This manual describes procedures to be followed when performing emergency procedures rescuing people from a CR-Z hybrid vehicle. For safety, read through the manual thoroughly and follow all instructions. All CR-Z cars employ an IMA system. IMA is an abbreviation for Integrated Motor Assist, which is a highly efficient hybrid system that in addition to the main gasoline engine also employs an electric motor (IMA motor) as an auxiliary engine. Honda Motor Co., Ltd. Safety Symbols Items with the following safety symbols explain particularly important information related to safety. Be sure to read the descriptions. DANGER Failure to follow these instructions will cause death or serious injury. WARNING Failure to follow these instructions could cause death or serious injury. CAUTION Failure to follow these instructions could cause injury.

Table of Contents 1. How to Identify a CR-Z 2 2. About Hybrid Vehicles 3 High voltage area 3 Isolating high voltage 4 Blocking high voltage 4 About the IMA battery 4 Action to take when the IMA battery fluid leaks 5 Securing and stabilizing the vehicle 5 3. Precautions During Emergency Procedures 6 Handling overview 6 Extracting a person from the vehicle 6 If the vehicle catches fire 7 If the vehicle is underwater 7 If the IMA battery is damaged 7 Pre-processing of auxiliary devices 7 Blocking high voltage 8 Precautions and actions when cutting into the vehicle 2 4. Guide to Transporting a Car That Has Been Involved in an Accident 14 Vehicle data 14 Towing guide 14 Eyebolt mounting position, towing hook, tie down slot position 15 High Voltage Warning Sign Final page

1. How to Identify a CR-Z 1. How to Identify a CR-Z The following section describes the external appearance and features of the CR-Z. If the car involved in the accident is the relevant model, follow all precautions outlined in this guide when performing emergency procedures. Exterior The antenna on the roof is unique. The following logos are visible on the rear of the vehicle. Interior Example of front side of inside the car. The switches on the right side of the handle are unique. There is a green ECON button. Identification by model The engraved plate inside the engine compartment or plate on the passenger s side seat door pillar indicates the model and frame number. The first 3 digits of the frame number indicates the model. (7 digit number) Example: ZF1 - CR-Z hybrids can be identified by the first 3 digits, which are ZF1. Impression 2

2. About Hybrid Vehicles 2. About Hybrid Vehicles The CR-Z s IMA system uses a high voltage of 100.8V. For that reason, when conducting emergency work you must exercise extreme care and follow the subsequent procedures. WARNING There is a possibility of severe burns or serious injury or death due to electric shock. If an orange high voltage cable or the high voltage cover is damaged or wires or pins are exposed, avoid contact with these areas. If you are not sure if exposed wires or pins are related to the high voltage area, do not touch them. Always wear insulation gloves and safety glasses if you will or are likely to come into contact with the IMA system. [Required items] The following items are required for emergency work: 1 Protectors (insulated gloves or rubber gloves, safety glasses, insulated footwear) 2 Saturated boric-acid liquid: 20L 3 Red litmus paper 4 ABC fire extinguisher 5 Rags, old towels 6 Insulated tape High voltage area The area surrounded by the red dashed line in the illustration indicates the high-voltage area. The high voltage cables are orange. IMA Battery (100.8 V) 12V Battery High voltage cable (orange) IMA Motor WARNING High voltage cables are laid under the floor. If the high voltage cable is damaged or cut, there is a risk of severe burns caused by high voltage due to exposed wiring, or injury or death due to electric shock. When hoisting or jacking up the vehicle, be careful not to allow objects to touch the high voltage cable. Note: When a vehicle is stored after being involved in an accident, use the High Voltage Work In Progress: Do Not Touch sign (at the end of this guide) to warn other people about the danger of high voltage. 3

2. About Hybrid Vehicles Isolating high voltage High voltage is isolated in the CR-Z. For the high voltage circuit, both the positive (+) and negative (-) poles are insulated from the body of the car. High voltage devices and high voltage cables are contained in a case or have a cover so that high voltage sections are not exposed. High voltage electrical components and the IMA battery are concentrated at the rear of the vehicle and are housed in a case. The high voltage cable in the engine compartment is also segregated by a cover. The high voltage cables are orange. A warning label is affixed to all high voltage areas. Blocking high voltage High voltage can be blocked in the CR-Z. Blocking of the high voltage circuit is interlocked with the ignition switch. When the ignition switch is turned OFF, the high voltage circuit is blocked. A main switch is also provided to manually block high voltage from the IMA battery. In the event of electric leakage or a short-circuit due to a collision or submerging of the vehicle, the motor control unit blocks high voltage. Tripping of the fuse also blocks high voltage. About the IMA battery In addition to a 12V vehicle battery, the CR-Z Vehicle front is also equipped with a high voltage IMA battery (battery for drive). The electrolyte in the IMA battery is composed of a strong alkaline potassium hydroxide solution (ph13 or higher). Usually the IMA battery is in a case and is stored under the floor in the rear of the vehicle, and you do not see the IMA battery itself. The electrolyte Main switch is sealed inside the IMA battery, so there is no IMA Battery (100.8 V) need for replacement or replenishment. Even if the IMA battery is damaged, there will not be a massive discharge of electrolyte. If the electrolyte does leak, it will just be at a bleeding or seeping level. For instructions on the proper handling in the case of leaked electrolyte, refer to the following section. DANGER If the electrolyte comes in contact with your skin, it may cause burns. If it comes into contact with your eyes, you risk partial or total blindness. Should the electrolyte come in contact with any unprotected part of your body, wash it off with a large quantity of water and go to a doctor for medical examination and treatment immediately. Always wear insulation gloves and safety glasses if you will or are likely to come into contact with the IMA system. 4

2. About Hybrid Vehicles Action to take when the IMA battery fluid leaks The IMA battery electrolyte is a strong alkaline and is therefore extremely harmful. It is colourless and odourless and therefore cannot be identified simply by looking at it. If you should find solution leakage near the IMA battery and suspect it to be electrolyte, use saturated boric-acid liquid to neutralize it. 1 When working, you must wear alkalineresistant rubber gloves and safety glasses. 2 Prepare red litmus paper and neutralizer (saturated boric-acid) beforehand. To create the neutralizer, mix 800g of powdered boric acid with 20 litres of water in a container. Boric acid 3 Apply a red litmus paper to the leaked solution to check if the color changes. If the red litmus paper turns blue, pour on the neutralizer (saturated boric-acid). Check again, and only when the litmus paper does not change colour, use a rag to wipe it off. 4 When performing neutralization outdoors, you must stand upwind. If you are indoors, be sure to perform the procedure in a well-ventilated room. 5 If your skin comes into contact with the elelctrolyte, rinse with a large amount of water immediately. If your clothes are exposed to the electrolyte, remove immediately. 6 If your eyes come into contact with the electrolyte, wash them with a large quantity of water and go to a doctor for medical examination and treatment immediately. Note: Red litmus paper and saturated boric-acid are available at your local drug store. There is no problem with flushing neutralized electrolytic solution down the drain or into the sewer system. Securing and stabilizing the vehicle Apply the parking brake to keep the vehicle from moving. Next, wedge a block of wood under the vehicle and deflate the tyres. Alternatively, use a rescue lift air bag device to stabilize the vehicle. [Important] When setting up the support object or lift air bag device you must avoid the high voltage area under the floor and the exhaust and fuel system. 5

3. Precautions During Emergency Procedures 3. Precautions During Emergency Procedures Handling overview As the CR-Z is also equipped with a gasoline engine, you must observe the same safety precautions that you employ when working with usual gasoline engine vehicles but also exercise due caution and take appropriate measures to deal with the high voltage unique to hybrid cars. Read through each of the following items and take appropriate action for the actual work depending on the situation. Extracting a person from the vehicle If it is necessary to secure a space to extract someone from the car, adjust the position of the steering wheel. Push up the lever and adjust the handle position front/back and up/down. In the same way, adjust the position of the front seat when more space is necessary. Repeatedly pull the lever up or down to adjust the height. While pulling up the lever, adjust the anteroposterior position. While pulling up the lever, adjust the angle of the back rest. 6

3. Precautions During Emergency Procedures If the vehicle catches fire If a vehicle catches fire, use an ABC fire extinguisher (one that can handle both oil and electrical fires), or drench the vehicle in large amounts of water. During a fire, the insulated coating of electric wiring burns, causing short-circuits and blowing of the fuses in the ignition system, eventually resulting in blocking of high voltage. The same occurs also due to the use of water on the electrical components. Depending on the location of the fire, fuses may not blow and electric leakage does not occur, thus high voltage may not be blocked. Therefore, after extinguishing the fire, block the high voltage as described on page 8, Blocking High Voltage. Note: None of the parts used in the IMA system are explosive. If the vehicle is under water When a vehicle is submerged under water, due to electrical leakage caused by water coming into the vehicle, short-circuits occur, causing blowing of the fuses in the ignition system or the main fuse of the IMA battery, resulting in blocking of high voltage. Depending on the situation, such as if the water level is low, in some cases the submerged part of the vehicle does not cause electric leakage due to immersion in water, so high voltage may not be blocked. You must, therefore, block high voltage as described on page 8, Blocking High Voltage. If the IMA battery is damaged In cases in which the IMA battery is damaged due to collision, never touch exposed pins, metal sections, or high voltage cables. If you cannot avoid touching such areas, always wear insulated gloves. In case of solution leakage, follow the description on page 5, Action to take when the IMA battery fluid leaks. WARNING There is a possibility of severe burns or serious injury or death due to electric shock. If an orange high voltage cable or the high voltage cover is damaged or wires or pins are exposed, avoid contact with these areas. If you are not sure if exposed wires or pins are related to the high voltage area, do not touch them. Always wear insulation gloves and safety glasses if you will or are likely to come into contact with the IMA system. Pre-processing of auxiliary devices Operate the power windows, door lock, tailgate, etc. as necessary. [Important] If you disconnect the 12V battery, operation of the above electrical components is disabled. 7

3. Precautions During Emergency Procedures Blocking high voltage Depending on the damage to the vehicle, block high voltage. You can use any of the following methods to block high voltage. After high voltage is blocked, emergency procedures can be performed. Check vehicle damage Can you operate the ignition switch? No Yes Method 1: Turn OFF the ignition switch (go to page 9) Can you open the tailgate? No Yes Method 2: Remove the 12V battery connection (go to page 10) Can you open the tailgate? Yes Method 3: Turn OFF the main IMA switch (go to page 11) No (When all three of the above methods are not possible) Unable to block high voltage correctly. Wear insulated gloves and insulated footwear as appropriate insulation measures and only then begin emergency procedures. If the high voltage area is damaged and wiring or pins are exposed, avoid contact and make sure neither you or any other part of the vehicle come into contact with these areas during emergency procedures. WARNING There is a possibility of severe burns or serious injury or death due to electric shock. If an orange high voltage cable or the high voltage cover is damaged or wires or pins are exposed, avoid contact with these areas. If you are not sure if exposed wires or pins are related to the high voltage area, do not touch them. Always wear insulation gloves and safety glasses if you will or are likely to come into contact with the IMA system. 8

3. Precautions During Emergency Procedures Method 1: Turn OFF the ignition switch. When the ignition switch can be operated though the vehicle is damaged Turn OFF the ignition switch. For CVT cars, set the select lever to D and then turn OFF the ignition switch. CAUTION The car is equipped with an auto idle stop system. Even when the engine is stopped, it does not mean that the ignition switch is OFF. Always turn the ignition switch to OFF (position 0). Note: The auto idle stop system automatically stops the engine when the car is coming to a halt and automatically restarts the engine when it begins moving again. Remove the key. If you cannot remove the key and are dealing with a car equipped with a Honda Smart Key, perform Method 2 or 3 described on the next two pages. Note: This procedure is performed because it is possible that blocked high voltage is unblocked due to unexpected turning ON of the ignition switch as a result of human error or for some other reason. The ignition switch section of cars equipped with a Honda Smart Key. It is not a key but is instead a knob. CAUTION After the ignition switch is turned OFF, it takes about 5 minutes to discharge electric charge accumulated in the capacitor, etc. Immediately after blocking high voltage, pay attention to short-circuits, etc. during work. Start the emergency procedure. 9

3. Precautions During Emergency Procedures Method 2: Disconnect the 12V battery. The ignition switch cannot be operated but the bonnet can be opened. Open the bonnet. Pull the bonnet release knob at the foot of the driver s seat toward you and press the lever in the front center of the bonnet to release the lock mechanism and open the bonnet. If this procedure is not possible, use a tool such as a crowbar to pry open the bonnet. If possible, use the stay included with the car to secure the opened bonnet. Hood release knob Press Lever Disconnect the 12V battery. Remove the negative (-) pin side cable from the 12V battery, then remove the positive (+) pin side cover and disconnect (or cut) pin A or pin B, as illustrated. Note: You must cut the electrical connection between pin A and pin B. It is not intended to remove the positive (+) pin from the 12V battery. Positive (+) pin Vehicle front Pin A Pin B Negative (-) pin Cover Positive (+) pin Vehicle front CAUTION After disconnecting the 12V battery, it takes about 5 minutes to discharge electric charge accumulated in the capacitor, etc. Immediately after blocking high voltage, pay attention to short-circuits, etc. during work. Start the emergency procedure. 10

3. Precautions During Emergency Procedures Method 3: Turn OFF the IMA main switch. When the ignition switch cannot be operated and the bonnet cannot be opened. Open the tailgate. Open the tailgate, remove all items from the luggage compartment and then remove the floor map, lid and box. The lid for the main switch is located on the floor. Main switch lid When a Honda Smart Key cannot be used or the tailgate lock does not operate when the driver s seat door lock is engaged, remove the maintenance lid (A) of the tailgate door lining from inside the car. To open the lock lever (B), use a flat-bladed screwdriver to press the lock lever (B) in the direction indicated by the arrow in the illustration. When you don t know how to open the lock lever or cannot operate from inside the car, use a tool such as crowbar to pry open the tailgate. A Press down Vehicle front (inside car) B Remove the the main switch cover. Loosen bolt (A) and remove bolt (B) and main switch cover (C). Continue to the next page 11

3. Precautions During Emergency Procedures Continued from the previous page Turn OFF the main switch. You must wear insulated gloves when turning OFF the main switch. Before turning OFF the main switch check that the bolt (D) is visible. Main switch D CAUTION After the main switch is turned OFF it takes about 5 minutes to discharge electric charge accumulated in the capacitor, etc. Immediately after blocking high voltage, pay attention to short-circuits, etc. during work. Start the rescue activity. Precautions and actions when cutting into a vehicle WARNING There is a possibility of severe burns or serious injury or death due to electric shock. If an orange high voltage cable or the high voltage cover is damaged or wires or pins are exposed, avoid contact with these areas. If you are not sure if exposed wires or pins are related to the high voltage area, do not touch them. Always wear insulation gloves and safety glasses if you will or are likely to come into contact with the IMA system. Do not cut the high voltage area. There is a possibility of serious injury due to fire started by sparks, therefore try to use a device such as a hydraulic cutter (that does not generate sparks) when performing cutting tasks. The air bag system is still active for three minutes after turning OFF the ignition switch or disconnecting the 12V battery, so allow three minutes to pass before you begin working. To rescue occupants by cutting into the vehicle, you must pay attention to undeployed air bags and high voltage areas. Careless cutting work could cause shorting of wires or unexpected deployment of the air bag, resulting in a secondary accident. Even after high voltage has been blocked, do not cut into the high voltage area. 12

3. Precautions During Emergency Procedures Air bag-related cautions Side air bag* Passenger side air bag Driver side air bag Left side impact sensor* Side curtain air bag* Front impact sensor Seat belt pretensioner SRS unit (front collision and side collision built-in sensor) *: Vehicle equipped with side air bags and side curtain air bags Right side impact sensor* Each air back and seat belt pretensioner contains a high pressure gas generator. Therefore, if the air bag has not yet been deployed, do not cut those parts. Do not cause impact or cut near sensors (areas indicated by red blocks in the illustrations above and to the right). However, if the air bag has already been deployed, or at least three minutes have passed since the ignition switch is turned OFF or the 12V battery is disconnected, there is no problem. You must be particularly careful, if the air bag has not yet been deployed, not to cut near the high pressure gas generator area of the side curtain air bag at the side of the body (the red section in the illustration). This illustration shows the left side of the car but the right side is the same. Area where impact and cut must be avoided Area where cut must be avoided Side curtain air bag* Precautions related to high voltage Regardless of equipment specifications, do not cut the high voltage cable or near the IMA battery, which are in the high voltage area in the undercarriage.in particular, do not cut into the IMA battery even after high voltage is blocked. High voltage cable (orange) IMA battery storage Front Bottom of body 13

4. Guide to Transporting a Car That Has Been Involved in an Accident 4. Guide to Transporting a Car That Has Been Involved in an Accident WARNING There is a possibility of severe burns or serious injury or death due to electric shock. If an orange high voltage cable or the high voltage cover is damaged or wires or pins are exposed, avoid contact with these areas. If you are not sure if exposed wires or pins are related to the high voltage area, do not touch them. Always wear insulation gloves and safety glasses if you will or are likely to come into contact with the IMA system. Vehicle data Model type Items Total length (mm) Total width (mm) Total height (mm) Wheel space (mm) Vehicle weight (kg) CR-Z 4,080 1,740 1,395 2,435 1,130 1,180 Towing guide When towing a vehicle, be sure to keep the following instructions in mind. Do not hook a towing rope to a location other than an eye bolt (a tie down slot can only be used to secure the vehicle). Do not attempt to use the bumper to lift the vehicle. Do not tow the vehicle in such a way that the vehicle is damaged. When towing a CVT car, set the select lever to D and then to N. If the vehicle does not go into neutral, tow the vehicle by lifting the four wheels. The towing speed must not exceed 30 km/h and the traveling distance must be within 80 km (except for towing on a flatbed truck). If the front and rear wheels do not move, tow the vehicle on a flatbed truck. Follow all road traffic regulations when towing. 14

4. Guide to Transporting a Car That Has Been Involved in an Accident When performing towing, always follow the instructions in the following table. Towing method Shift position MT car CVT car Conditions and precautions Towing using a rope Neutral N 1 Set the ignition switch to ACC (I) or ON (II). 2 Release the parking brake. Check that the transmission fluid is at the specified level. (If there is insufficient transmission fluid, tow the vehicle on a flatbed truck.) Towing by lifting the front wheels Neutral N Release the parking brake. Towing on a flatbed truck Neutral P The vehicle must be properly secured to keep it from coming off of the vehicle. Set the parking brake. Towing by trekker Neutral N Release the parking brake. [Reference] If the 12V battery is exhausted or disconnected, you may not be able to switch from position P. Eyebolt mounting position, towing hook, tie down slot position Front tie down slot Rear tie down slot Press Eye bolt attachment position Rear towing hook 15

Memo 16

High Voltage Warning Sign High Voltage Work In Progress: Do Not Touch! Person in charge High Voltage Work In Progress: Do Not Touch! Person in charge Make copies and paste them in high visibility locations.

I HHR005 Honda Motor Co., Ltd. 4-Wheel Quality Service Department