HIGH VOLTAGE SERVICE CAUTIONS

id000000748900

Warning

<<High voltage>>

•  Vehicles damaged in an accident could have electrical leakage due to internal damage of the high voltage battery. If servicing is carried out under electrical leakage conditions, it could cause electrical shock and result in serious injury or, in the worst case, death. When handling a vehicle damaged in an accident, follow the cautions and perform the correct procedures.

•  Refer to [Handling high voltage battery on damaged vehicle] in [DAMAGED VEHICLE HANDLING] in the general information and determine if an internal inspection of the high voltage battery is necessary.(See DAMAGED VEHICLE HANDLING [(E)].) Perform servicing only if an internal inspection of the high voltage battery is unnecessary. If it is determined that an internal inspection of the high voltage battery is necessary, contact the technical assistance for your market without performing servicing.

•  The inspection and removal/installation of the high voltage parts of this vehicle must be performed by persons who have acquired qualifications specified by the laws and regulations.

•  The protective equipment indicated in the workshop manual is recommended by Mazda. Use equipment specified by the laws and regulations of each country.

•  Wear insulating gloves when inspecting or removing/installing the high voltage parts. Touching the high voltage parts without wearing insulating gloves could cause electrical shock and result in serious injury or, in the worst case, death.

•  Before inspecting or removing/installing the high voltage parts, remove the service plug and wait until 10 min have elapsed. Servicing without removing the service plug or before 10 min have elapsed after removing the service plug could cause electrical shock and result in serious injury or, in the worst case, death. Refer to the Workshop Manual for the [SERVICE PLUG REMOVAL/INSTALLATION].

•  Do not spin the tires while inspecting or removing/installing the high voltage parts. If the tires spin, power generation occurs even if the service plug is removed. If power generation occurs, it could cause electrical shock and result in serious injury or, in the worst case, death.

•  Verify that the charge connector is not connected to the vehicle when inspecting or removing/installing the high voltage parts. If the charge connector is connected to the vehicle, high voltage may be supplied to the vehicle. If this occurs, it could cause electrical shock and result in serious injury or, in the worst case, death.

•  Always observe the following thoroughly to ensure safety when inspecting or removing/installing the high voltage parts. Otherwise, the high voltage circuit may operate on the vehicle regardless of whether or not the main power is switched OFF or ON (READY off or on). If this occurs, it could cause electrical shock and result in serious injury or, in the worst case, death.

―  Do not select high voltage battery cooling on center display after EV system stops

―  Do not open/close doors frequently with main power switched OFF

―  Do not perform normal charging or quick charging

―  Switch to connected vehicle maintenance mode (MyMazda App connected vehicle)

―  Cancel climate control timer

―  Operate center display and turn off battery heater operation

•  When inspecting or removing/installing the high voltage parts, place a high voltage work sign on the vehicle to alert other workers.

Caution

<<High voltage>>

•  Do not switch the main power ON (READY on) after removing the service plug. If the main power is switched ON (READY on) after removing the service plug, a malfunction may occur with the vehicle.

Note

•  The high voltage parts can be identified as follows.

―  Parts that are connected using orange wiring harnesses

―  Parts with a high voltage warning label attached

Identification of High Voltage Wiring Harnesses and Equipment

―  The high voltage cable and connectors are covered by orange insulation as a standard.

―  A warning label is attached to the high voltage equipment (high voltage battery and inverter) indicating the presence of high voltage inside the equipment.

a30zzw00000894

Handling of High Voltage Connectors and Terminals

Items Prohibited from Being Held or Worn

High Voltage Work Indication

•  When inspecting or removing/installing the high voltage parts, place a high voltage work sign on the vehicle to alert other workers.

High voltage work sign

a30zzw00001980

High Voltage Cut-off

Protective equipment

Warning

<<High voltage>>

•  The protective equipment indicated in the workshop manual is recommended by Mazda. Use equipment specified by the laws and regulations of each country.

•  Perform periodic inspections specified by the laws and regulations for protective equipment to be used when performing high voltage work and use products that have no defects and are in good condition.

•  If insulating gloves that are defective or are in poor condition are used when performing high voltage work, it could cause electrical shock and result in serious injury or, in the worst case, death. Perform an inspection before using insulating gloves and verify that they are not defective and in good condition.

•  Do not test insulating gloves by blowing exhaled air into them. Moisture in the gloves could cause electrical shock and result in serious injury or, in the worst case, death.

Inspection before use

•  The person who is going to perform the work must inspect the protective equipment and tools for wear and damage before using them.

•  Always verify that the insulating gloves are free of scratches, holes, tears, and cracks before use using the following methods. In addition, do not use wet or damp insulating gloves.

1.  Visually inspect the entire outer surface of the insulating gloves to verify that they are free of damage.

2.  Open the cuff of the insulated glove and put air into it. (Fig. 1)

3.  Fold the cuff and roll it up to the wrist of the glove to prevent air from leaking. (Fig. 2)

4.  Fold the rolled cuff to seal the air in. (Fig. 3)

5.  Hold the glove against an ear to verify that there is no air leakage. (Fig. 4)

Note

•  If there is a hole or tear in the insulated glove, an air leaking sound is heard.

adejjw00008320

High voltage cut-off procedure

Items to be prepared

a30zzw00004976

Measurement Device Handling

Measurement device	Purpose	Handling method	Handling cautions
Insulation resistance tester	Used to check the insulation resistance of high voltage parts Note •  Apply a high voltage to the measuring section from the tester side and measure the resistance based on the value of the current that flows	•  Set the measurement range to the 500 V range, and apply the lead wire to the inspection point	•  Wear insulating gloves when applying high voltage (500 V) to the measurement location •  Use the 500 V range to prevent damage to the parts. (Use in the 1000 V range may damage the internal circuit)
Milliohm tester	Used to measure the resistance of the motor coils	•  Warm up before use •  Apply the lead wire to the measuring point	•  Accurate values cannot be obtained if measurement is performed without warming up
Voltmeter	Use when checking for open or short circuits by voltage, or electrical signals by voltage	•  Set positive lead wire to voltage measurement location, negative lead wire to ground	•  Connect voltmeter in parallel to circuit •  Use range appropriate to voltage to be measured •  When setting positive lead wire to narrow terminal, wrap thin wire around lead wire to set

High Voltage Part Inspection And Removal/Installation Notes

Warning

<<High voltage>>

•  The inspection and removal/installation of the high voltage parts of this vehicle must be performed by persons who have acquired qualifications specified by the laws and regulations.

•  The protective equipment indicated in the workshop manual is recommended by Mazda. Use equipment specified by the laws and regulations of each country.

•  Wear insulating gloves when inspecting or removing/installing the high voltage parts. Touching the high voltage parts without wearing insulating gloves could cause electrical shock and result in serious injury or, in the worst case, death. (See HIGH VOLTAGE SERVICE CAUTIONS.)

•  Before inspecting or removing/installing the high voltage parts, remove the service plug and wait until 10 min have elapsed. Servicing without removing the service plug or before 10 min have elapsed after removing the service plug could cause electrical shock and result in serious injury or, in the worst case, death. Refer to the Workshop Manual for the [SERVICE PLUG REMOVAL/INSTALLATION].

•  Do not spin the tires while inspecting or removing/installing the high voltage parts. If the tires spin, power generation occurs even if the service plug is removed. If power generation occurs, it could cause electrical shock and result in serious injury or, in the worst case, death.

•  Verify that the charging connector is not connected to the vehicle when inspecting or removing/installing the high voltage parts. If the charging connector is connected to the vehicle, high voltage may be supplied to the vehicle. If this occurs, it could cause electrical shock and result in serious injury or, in the worst case, death.

•  Always observe the following thoroughly to ensure safety when inspecting or removing/installing the high voltage parts. Otherwise, the high voltage circuit may operate on the vehicle regardless of whether or not the main power is switched OFF or ON (READY off or on). If this occurs, it could cause electrical shock and result in serious injury or, in the worst case, death.

―  Do not select high voltage battery cooling on center display after EV system stops

―  Do not open/close doors frequently with main power switched OFF

―  Do not perform normal charging or quick charging

―  Switch to connected vehicle maintenance mode (MyMazda App connected vehicle)

―  Cancel climate control timer

―  Operate center display and turn off battery heater operation

•  When inspecting or removing/installing the high voltage parts, place a high voltage work sign on the vehicle to alert other workers.

Caution

<<High voltage>>

•  Do not switch the main power ON (READY on) after removing the service plug. If the main power is switched ON (READY on) after removing the service plug, a malfunction may occur with the vehicle.

Note

•  The high voltage parts can be identified as follows.

―  Parts that are connected using orange wiring harnesses

―  Parts with a high voltage warning label attached

Service Plug Removal

1.  Verify that the READY indicator on the instrument cluster is not illuminated.

•  If the READY indicator is turned on, switch the main power OFF.

2.  Disconnect the negative lead-acid battery terminal. Refer to the Workshop Manual for the [NEGATIVE LEAD-ACID BATTERY TERMINAL DISCONNECTION/CONNECTION].

3.  Partially peel back the cover.

a30zzw00004019

4.  Remove the service hole cover.

a30zzw00004020

5.  Wear insulating gloves and remove the service plug using the following procedure.

Warning

<<High voltage>>

•  Touching the terminal on the vehicle side can result in serious injury or death from electric shock. For this reason, after removing the service plug, cover the vehicle-side terminals with insulating tape so that they cannot be touched.

•  Do not touch high voltage parts for 10 min after removing service plug. Electric charges may be stored on the condenser for 10 min after the service plug is removed, and touching high voltage parts during that time can result in serious injury or death from electric shock.

•  Service plugs must be removed by workers inspecting/removing/installing high voltage parts. Keep the removed service plug on your person until inspection/removal/installation of the high voltage parts is completed to prevent other workers from accidentally installing the service plug.

Caution

<<High voltage>>

•  After removing the service plug, cover the vehicle side terminals with insulating tape to prevent foreign matter from adhering to them.

•  When you are keeping the service plug on your person, cover the service plug terminals with insulating tape to prevent damage to them.

•  Do not switch the main power ON (READY on) after removing the service plug. If the main power is switched ON (READY on) after removing the service plug, the vehicle may malfunction.

(1)  Slide the lock in the direction of the arrow shown in the figure. (Do not pull out completely)

a30zzw00004021

(2)  Raise the lever.

a30zzw00004502

(3)  Press the area indicated by arrow (1) shown in the figure, release the tabs, and then raise the lever until it is perpendicular.

a30zzw00004503

(4)  Hold the lever and pull the service plug straight up.

a30zzw00004023

6.  After removing the service plug, leave it for 10 min.

7.  Wear insulating gloves and measure the voltage at the high voltage cable connection (junction box No.3 side) using the following procedure.

(1)  Remove the seal cover. Refer to the Workshop Manual for the [SEAL COVER REMOVAL/INSTALLATION].

Caution

<<High voltage>>

•  Be careful not to allow foreign matter or water droplets to enter the junction box No.3. Since the junction box No.3 has a high voltage circuit, there is a risk of malfunction if foreign matter or water drops enter it.

•  Remove the terminal cover by pulling it straight up. The terminal cover is fitted with an interlock switch. This interlock switch may be damaged if the terminal cover is removed while being tilted.

•  Do not touch the moisture-proof seal on the terminal cover. If the seal is touched or damaged, replace the terminal cover.

a30zzw00004024

(2)  Remove the terminal cover. Refer to the Workshop Manual for the [HIGH VOLTAGE CABLE REMOVAL/INSTALLATION].

(3)  Measure the voltage at the HV cable connection.

Note

•  Use a voltmeter with a measurement range of 450 V DC or more.

a30zzw00004025

―  Verify that the voltmeter indicates 0 V and go to the next step.

•  Verify that the waterproof rubber on the terminal cover is securely installed.

•  Be careful not to damage the interlock, and install it securely.

(4)  Install the terminal cover. Refer to the Workshop Manual for the [HIGH VOLTAGE CABLE REMOVAL/INSTALLATION].

Service Plug Installation

Caution

•  Before connecting the service plug, check the tightness of the high voltage terminals and the connection status of the connectors.

1.  Wear insulating gloves and install the service plug using the following procedure.

(1)  Insert the service plug as far as it will go.

a30zzw00004026

(2)  Depress the lever completely.

a30zzw00004027

(3)  Slide the lock in the direction of the arrow shown in the figure until the hook is engaged.

a30zzw00004028

2.  Install the service hole cover.

a30zzw00004020

3.  Close the cover.

a30zzw00004029

4.  Connect the negative lead-acid battery terminal. Refer to the Workshop Manual for the [NEGATIVE LEAD-ACID BATTERY TERMINAL DISCONNECTION/CONNECTION].

Handling High Voltage Battery