Navistar International eMV Series User manual

InstructionSheet
FIRSTRESPONDERGUIDE-International®eMV™Series
4328810R1
Purpose
Thepurposeofthisdocumentistoprovidedetailedinstructiononthefollowingforrstresponders:
•Safetyinformation
•High-voltagelabels
•PersonalProtectionEquipment(PPE)
•Identifythevehicle:exterior
•Identifythevehicle:interior
•Identifythevehicle:underhood
•Overview:vehiclesystemsandcomponents
•High-voltagebattery
•Drivemotor
•High-voltagecables
•Immobilization
•Disabledirecthazards
•Storedenergy/liquids
•Hazardousmaterialemergencycleanup
•Incaseofre
•Incaseofsubmersion
•Towing/transportation/storage
•Importantadditionalinformation
1
Readallsafetyinstructionsinthe"SafetyInformation"sectionoftheappropriateEngineServiceorDiagnosticManual.
Followallwarnings,cautions,andnotes.
©2021Navistar,Inc.Allrightsreserved.Allmarksaretrademarksoftheirrespectiveowners.

SafetyInformation
NOTE:Certainwarningsmayberepeatedthroughoutthismanual.
WARNING:Topreventpersonalinjuryand/ordeath,removealljewelrysuchaswatches,
necklaces,andearrings.Removeallmetalobjectsthatareconductorsofelectricity.
WARNING:Topreventpersonalinjuryand/ordeath,ALWAYSapproachthevehiclefromthesides
wheneverpossibletostayoutofpotentialtravelpath.Itmaybedifculttodetermineifthevehicleis
runningduetolackofenginenoise.
WARNING:Topreventpersonalinjuryand/ordeath,ordamagetoproperty,removeanycharge
cablefromthevehicle,turnignitionOFF,setparkingbrake,andinstallwheelchockstopreventvehicle
frommovingineitherdirectionduringfurtheraction.
WARNING:Topreventpersonalinjuryand/ordeath,donottouchthehigh-voltagesystemorany
ORANGEdevicewithoutwearingappropriatehigh-voltagePersonalProtectionEquipment(PPE).The
PPEshouldinclude:
a.Class0electricalinsulatinggloves,safetygoggles,andElectricalHazard(EH)ratedsafetyshoes
orboots,whichmustbeatleastappropriateupto1,000volts.
b.Anon-conductiveobject,about5ft(1.5m)long,tosafelypushsomeoneawayfromthevehicle
iftheyaccidentallycomeincontact.
WARNING:Topreventpersonalinjuryand/ordeath,turnOFFthe12Vdisconnectswitchand
high-voltagedisconnectswitchbeforeinteractingwithadamagedvehicle.
WARNING:Topreventpersonalinjuryand/ordeath,ALWAYSREMEMBERthe12VoltBattery
DisconnectSwitchonlydisablesthevehicle12voltsystem,NOTthehigh-voltagebatterysystem.
WARNING:Topreventpersonalinjuryand/ordeath,ALWAYSREMEMBERthatturningOFFthe
high-voltagedisconnectswitchwillnotdissipatevoltageinsidethehigh-voltagebatteriesorinlevel
2or3high-voltagecables.ALWAYSASSUMEthehigh-voltagebatteries,high-voltagecables,and
high-voltagecomponentsremainliveanddangerous.Contactwiththehigh-voltagebatterypackor
high-voltagecomponentinternalsmayresultinseriouspersonalinjuryordeath.
WARNING:Topreventpersonalinjuryand/ordeath,handleasubmergedvehiclewithappropriate
PersonalProtectionEquipment(PPE).Considertheentirevehicleasenergized.
WARNING:Topreventpersonalinjuryand/ordeath,alwayswearfullPersonalProtection
Equipment(PPE),includingSelf-ContainedBreathingApparatus(SCBA)whenreisinvolved.Fires
incrash-damagedelectricvehiclescouldemittoxicorcombustiblegasses.Smallamountsofeye,
skin,orlungirritantsmaybepresent.Ifexposed,rinsewithlargeamountsofwaterfor10-15minutes.
Considertheentirevehicleasenergized.
WARNING:Topreventpersonalinjuryand/ordeath,NEVERcutorattempttobreachhigh-voltage
batteries,high-voltagecomponents,orhigh-voltagewiring.
WARNING:Topreventpersonalinjuryand/ordeath,payattentiontosecondaryreevents.Even
dayslatersecondaryreeventscannotbeexcluded.
4328810R12
©2021Navistar,Inc.Allrightsreserved.Allmarksaretrademarksoftheirrespectiveowners.

High-VoltageLabels
Figure1.ExtractofAvailableHigh-VoltageLabelsThroughouttheEntireVehicle
Varioushigh-voltagecomponentsareinstalledthroughouttheentirevehicle.Atrianglewithalightningboltis
usedtoidentifyhigh-voltagecomponents.Thelightningtrianglecanbesingleorpartofacombination.Also,any
vehiclecomponentsthatareORANGEincolorand/orORANGEwithstripesidentifyhigh-voltagecomponents.
High-voltagecomponentsinthevehiclearedividedintothreelevels/zones.Onlycomponentsatlevel1/zone
1areisolatedafterthehigh-voltagedisconnectswitchisturnedOFF .Componentsinzone2andzone3remain
live.
34328810R1
©2021Navistar,Inc.Allrightsreserved.Allmarksaretrademarksoftheirrespectiveowners.

High-VoltageLabels(cont.)
2
0000469818
Figure2.Level2/Zone2:High-voltagecablesareORANGEwithBLUEstripingandhaveWHITE
andBLUEsafetyags.
3
0000469819
Figure3.Level3/Zone3:High-voltagecablesareORANGEwithWHITEstripingandhaveBLACK
andWHITEsafetyags.
WARNING:Topreventpersonalinjuryand/ordeath,ALWAYSREMEMBERthatturningOFFthe
high-voltagedisconnectswitchwillnotdissipatevoltageinsidethehigh-voltagebatteriesorinlevel
2or3high-voltagecables.ALWAYSASSUMEthehigh-voltagebatteries,high-voltagecables,and
high-voltagecomponentsremainliveanddangerousunlesshighvoltageisisolatedandtheisolation
isveried.Contactwiththehigh-voltagebatterypackorhigh-voltagecomponentinternalsmayresult
inseriouspersonalinjuryordeath.
Componentsinhigh-voltagezone2andhigh-voltagezone3remainliveafterthehigh-voltagedisconnectswitch
isturnedOFF.Thesezonesaremostlylocatedbetweentheframerailsontheundersideofthevehicleandare
labeledasindicatedinFigure2andFigure3.
4328810R14
©2021Navistar,Inc.Allrightsreserved.Allmarksaretrademarksoftheirrespectiveowners.

High-VoltageLabels(cont.)
0000470783
LEVE L 1 LEVE L 2 LEVE L 3
3
2
Figure4.High-VoltageIsolationLevels/Zones(ViewedfromBottom)
Thelevel1,2,and3zonesarelocatedasshowninFigure4.
54328810R1
©2021Navistar,Inc.Allrightsreserved.Allmarksaretrademarksoftheirrespectiveowners.

PersonalProtectionEquipment(PPE)
WARNING:Topreventpersonalinjuryand/ordeath,removealljewelrysuchaswatches,
necklaces,andearrings.Removeallmetalobjectsthatareconductorsofelectricity.
WARNING:Topreventpersonalinjuryand/ordeath,donottouchthehigh-voltagesystemorany
ORANGEdevicewithoutwearingappropriatehigh-voltagePersonalProtectionEquipment(PPE).The
PPEshouldinclude:
a.Class0electricalinsulatinggloves,safetygoggles,andElectricalHazard(EH)ratedsafetyshoes
orboots,whichmustbeatleastappropriateupto1,000volts.
b.Anon-conductiveobject,about5ft(1.5m)long,tosafelypushsomeoneawayfromthevehicle
iftheyaccidentallycomeincontact.
AvehiclewithDAMAGEDhigh-voltagecomponentsorwithUNKNOWNsafetystatusshouldonlybehandled
byspecialtrainedandequippedpersonnel.ThePersonalProtectionEquipmentmustbeatleastappropriateup
to1,000volts.Considertheentirevehicleasenergized.
AlwayswearfullappropriatePersonalProtectionEquipment(PPE),includingSelf-ContainedBreathing
Apparatus(SCBA),whenreisinvolvedorthevehiclewassubmergedduetothehighriskofreignition.
OnanInternational®eMV™SeriesWITHOUTanydamage,theignition,12Vdisconnectswitch,and
high-voltagedisconnectswitcharedesignedtobeoperatedwithoutanyspecialhigh-voltagePersonal
ProtectionEquipment(PPE).Donottouchanyotherhigh-voltagecomponentorORANGEcoloreddevice
withoutappropriateprotection.
4328810R16
©2021Navistar,Inc.Allrightsreserved.Allmarksaretrademarksoftheirrespectiveowners.

IdentifytheVehicle:Exterior
Figure5.ExteriorBadges
TheInternational®eMV™Seriescanbedistinguishedontheexteriorfromcommontruckmodelsbybadgeson
theleftandrightfrontdoorsandbyaBLUEELECTRICbadgeoneithersideofthehood.Thepositioningof
thesebadgesisidenticalforboththeleftsideandtheridesideofthevehicle.
IdentifytheVehicle:UnderHood
Figure6.UnderHood
Underhood,theInternational®eMV™Serieshasseveralhigh-voltagemodules,whichcanbedistinguishedby
theORANGEcablesandhigh-voltagelabels.
74328810R1
©2021Navistar,Inc.Allrightsreserved.Allmarksaretrademarksoftheirrespectiveowners.

IdentifytheVehicle:Interior
Figure7.Cluster
1.Chargingstationicon
TheInternational®eMV™Seriescanbedistinguishedfromcommonmediumdutytruckmodelsbythecharging
stationicon(Figure7,Item1)onthetopleftoftheinstrumentcluster.
4328810R18
©2021Navistar,Inc.Allrightsreserved.Allmarksaretrademarksoftheirrespectiveowners.

VehicleSystemsandComponents
Figure8.VehicleOverview
1.Drivemotor
2.TractionPowerInverterModule(TPIM)
3.S-boxandHigh-VoltageDistributionModule(HVDM)
4.High-voltagebatterystack(3)
5.DCDCconverters(DCDC)and12Vbatteries(insidestairbox)
6.2-in-1inverter
7.On-BoardCharger(OBC)(2)(underItem6)
8.High-voltagepowersteeringpump(locatedbehindfrontcoolingsystem)
9.High-VoltageDistributionUnit(HVDU)
10.High-voltageaircompressor(insidestairbox)
11.Chargeport(high-voltage)
12.BatteryThermalManagementSystem(BTMS)
94328810R1
©2021Navistar,Inc.Allrightsreserved.Allmarksaretrademarksoftheirrespectiveowners.

VehicleSystemsandComponents(cont.)
Figure9.12VandHigh-VoltageDisconnectSwitch
1.12Vbatterycompartment
2.High-voltagedisconnectswitch(locatedinsideofcab)
3.12Vdisconnectswitch
Thehigh-voltagedisconnectswitchand12Vdisconnectswitch(Figure9,Items2and3)arelocatedonthe
driversideofthevehicle.
4328810R110
©2021Navistar,Inc.Allrightsreserved.Allmarksaretrademarksoftheirrespectiveowners.

High-VoltageBatteries
Figure10.High-VoltageBatteries(ViewedfromUnderVehicle)
TheInternational®eMV™Seriesisequippedwiththreehigh-voltagebatterystacks.Eachstackcontainstwo
verticallystackedhigh-voltagebatteries.Thehigh-voltagebatteriesarebetweenthevehicleframerails,both
underthecabandtotherearofit.
DriveMotor
Figure11.DriveMotor(ViewedfromUnderVehicle)
Thedrivemotorislocatedbehindtherearaxleandispoweredby6-phasealternatingcurrent(AC).Thedrive
motorandthedifferentialareconnectedbyadriveshaft.
114328810R1
©2021Navistar,Inc.Allrightsreserved.Allmarksaretrademarksoftheirrespectiveowners.

High-VoltageCables
Figure12.High-VoltageCables(ViewedfromUnderVehicle)
WARNING:Topreventpersonalinjuryand/ordeath,NEVERcutorattempttobreachhigh-voltage
batteries,high-voltagecomponents,orhigh-voltagecableswhenhighvoltageispresent.
High-voltagecablesarecoloredinORANGEand/orORANGEwithstripes.DONOTcut,breach,orstress
ORANGEhigh-voltagecomponentsunlesshigh-voltageinthecorrespondingzonehasbeenisolated:
•HighvoltageinZone1isisolatedwhenLevel1ManualServiceDisconnects(MSDs)aredisconnected.
•HighvoltageinZone2isisolatedwhenLevel2MSDsaredisconnected.
•NEVERcutorattempttobreachhigh-voltagebatteries,high-voltagecomponents,orhigh-voltagecablesin
Zone3.
RefertoDisableDirectHazardsonthefollowingpagesfordetailedinstructions.
4328810R112
©2021Navistar,Inc.Allrightsreserved.Allmarksaretrademarksoftheirrespectiveowners.

DisableDirectHazards
TurningOFFtheVehicle
Figure13.Dashboard
1.Parkingbrakeknob(parkposition)
2.Neutralselectorbutton
3.Vehiclekey(OFFposition)
1.PushNeutral(N)button(Figure13,Item2).
2.Settheparkingbrakebypullingtheparkingbrakeknob(Figure13,Item1).
3.Turnthekey(Figure13,Item3)tothelefttoturnOFFthevehicle.
4.Removethekey.
134328810R1
©2021Navistar,Inc.Allrightsreserved.Allmarksaretrademarksoftheirrespectiveowners.

DisableDirectHazards(cont.)
TurningOfftheHigh-VoltageDisconnectSwitch
Figure14.12VandHigh-VoltageDisconnectSwitches
1.12Vbatterycompartment
2.High-voltagedisconnectswitch(locatedinsideofcab)
3.12Vdisconnectswitch
WARNING:Topreventpersonalinjuryand/ordeath,ALWAYSREMEMBERthehigh-voltage
disconnectswitchonlydisablesthevehicle’shigh-voltagesystem.Thehigh-voltagedisconnectswitch
doesNOTturnOFFthevoltageintheS-box,thehigh-voltagebatteries,andthecablesbetweenthese
items.Thevehicle12voltsystemcouldstillbeenergized.ALWAYSturnOFFboththehigh-voltage
disconnectswitchandthe12Vdisconnectswitchwheneverinteractingwithadamagedvehicle.NEVER
touchORANGEcableswithoutwearingappropriatePersonalProtectionEquipment(PPE).
1.Openthedriver-sidedoor.
2.TurntheREDhigh-voltagedisconnectswitchtoOFFposition(Figure14Item2).
3.LocktheswitchwithapadlocktoavoidanyonefromturningitbackON.
Componentsinhigh-voltagezone2andhigh-voltagezone3remainliveafterthehigh-voltagedisconnectswitch
isturnedOFF .Thesezonesarelocatedprimarilybetweentheframerailsontheundersideofthevehicleand
arelabeledasindicatedinFigure4.
4328810R114
©2021Navistar,Inc.Allrightsreserved.Allmarksaretrademarksoftheirrespectiveowners.

DisableDirectHazards(cont.)
TurningOffthe12VBatteryDisconnectSwitch
Figure15.12VandHigh-VoltageDisconnectSwitches
1.12Vbatterycompartment
2.High-voltagedisconnectswitch(locatedinsideofcab)
3.12Vdisconnectswitch
WARNING:Topreventpersonalinjuryand/ordeath,turnOFFthehigh-voltagedisconnectswitch
rstandthenturnOFFthe12Vdisconnectswitchbeforeinteractingwithadamagedvehicle.
WARNING:Topreventpersonalinjuryand/ordeath,ALWAYSREMEMBERthe12Vdisconnect
switchonlydisablesthevehicle12voltsystem,NOTthehigh-voltagebatterysystem.
1.TurntheRED12VdisconnectswitchtoOFFposition(Figure15,Item3).
2.LocktheswitchwithapadlocktoavoidanyonefromturningitbackON.
154328810R1
©2021Navistar,Inc.Allrightsreserved.Allmarksaretrademarksoftheirrespectiveowners.

DisableDirectHazards(cont.)
DisconnectingManualServiceDisconnects(MSD)
Figure16.MSDLocations
1.Level2MSDs2.Level1MSDs
TherearetwosetsofMSDsonthevehicle.Theyshouldbedisconnectedinthefollowingorder:
1.Thelevel1MSDs,locatedontheS-box(Figure16,Item2).
2.Thelevel2MSDs,locatedontheundersidecenterofthevehicle(Figure16,Item1).
4328810R116
©2021Navistar,Inc.Allrightsreserved.Allmarksaretrademarksoftheirrespectiveowners.

DisableDirectHazards(cont.)
Figure17.Level1ManualServiceDisconnects(MSDs)
1.S-box
2.Leverreleasetab
3.MSD(2total)
4.Redlockingtab
TheLevel1MSDs(Figure17,Item3)arelocatedontheS-box(Item1)andcanbeaccessedfromthedriver
sideofthevehicle.
Eachlevel1MSDcanberemovedbypullingtheREDlockingtab(Item4)out,pressingtheleverreleasetab
(Item2),andthenpullingthereleasehandledownwardapproximately45degrees.
RemovingthesetwoMSDsphysicallydisconnectshighvoltageaftertheS-box,isolatinghighvoltageawayfrom
high-voltageisolationzone1.Highvoltagewillstillexistinhigh-voltageisolationzones2and3.
174328810R1
©2021Navistar,Inc.Allrightsreserved.Allmarksaretrademarksoftheirrespectiveowners.

DisableDirectHazards(cont.)
Figure18.Level2ManualServiceDisconnects(MSDs)
1.MSD(2)
TheLevel2manualservicedisconnects(Figure18,Item2)arelocatedunderthevehicle,justforwardofthe
frontaxle.
EachLevel2MSDcanberemovedbypullingouttheREDlockingtabwhilepullingthereleasehandledown
approximately45degrees.
RemovingthesetwoMSDsphysicallydisconnectshighvoltagebetweentheS-boxandthebatterystacks,
isolatinghighvoltageawayfromhigh-voltageisolationzone2.Highvoltagewillstillexistinhigh-voltageisolation
zone3(theHVbatteriesandlevel3cables).
4328810R118
©2021Navistar,Inc.Allrightsreserved.Allmarksaretrademarksoftheirrespectiveowners.

StoredEnergy/Liquids
Lithiumironphosphatebatteriesareusedinthehigh-voltagesystem.Thesecellsaredrycells.Mostofthe
electrolytestoredinthesebatteriesisabsorbedbyactivematerials.Thereisonlyasmallamountofuid,which
mayleakifdamaged.Leakingelectrolytewilloccurindrops,notpuddles.Theuidisclearincolorwithasweet
ether-typeodor.Thesmellmayindicateabatteryleak.Calltheredepartmentimmediately.
Thehigh-voltagebatteries,on-boardchargers,DC-DCconverters,TractionPowerInverterModule(TPIM),and
drivemotorareliquidcooledwithaglycol-basedautomotivecoolant.ThisliquidisREDincolorandmayleak
incaseofadamagedcoolingsystem.
HazardousMaterialEmergencyCleanup
Followinganelectricvehicleaccident/incident,hazardousmaterialsneedtobecleanedupappropriately.
Pleasecontactyourlocalandstateauthoritiesformoreinformationregardingproperresponseandcleanup
ofhazardousmaterials.
InCaseofFire
WARNING:Topreventpersonalinjuryand/ordeath,alwayswearfullPersonalProtection
Equipment(PPE),includingSelf-ContainedBreathingApparatus(SCBA)whenreisinvolved.Fires
incrash-damagedelectricvehiclescouldemittoxicorcombustiblegasses.Smallamountsofeye,
skin,orlungirritantsmaybepresent.Ifexposed,rinsewithlargeamountsofwaterfor10-15minutes.
Considertheentirevehicleasenergized.
WARNING:Topreventpersonalinjuryand/ordeath,payattentiontosecondaryreevents.There
isahighriskofreignitionafterreisextinguished.
Flames,smoke,arcingorhotspotslikemeltedplasticmayindicatereorthepresenceofhighvoltage.A
thermalcameraorIRtemperatureprobemaybeusefultoidentifyhotspots.Ifsignsofrearenoted,callthe
localredepartmentimmediately.Cleartheareaaroundthevehicleifpossibleandopenthevehicledoorsto
avoidbuild-upofgasesinthepassengercompartment.Ifabatteryhasstartedburning,itwilltrytoburnto
completion.Cooldownthebatterieswithdirectandlargeamountsofwater.Ifpossible,removecombustible
materialsfromaroundthevehicletopreventregrowth.
Batteriesmustbecompletelycooleddownbeforereleasingthevehicletosecondresponder.Advisesecond
responderthatthereisalwaysariskofreignition.
194328810R1
©2021Navistar,Inc.Allrightsreserved.Allmarksaretrademarksoftheirrespectiveowners.

InCaseofSubmersion
Incaseofsubmersion,secondaryimpactdamagecanneverbeexcluded.Damagedhigh-voltagecomponents
poseanincreasedelectricalshockhazard.Stayawayfromdamagedhigh-voltagecomponents.Handleany
fullyorpartiallysubmergedvehiclewhilewearingtheappropriatePersonalProtectionEquipment(PPE).
Asubmergedvehiclewithoutimpactdamagehasalowelectricalshockhazardrisk.Smallbubblesmaybe
noticedexitingthevehicle.Thisisduetoelectrolysisofthewateranddoesnotcreateahigherriskofshock
hazard.
WARNING:Topreventpersonalinjuryand/ordeath,considertheentirevehicleasenergized.
AlwayswearfullPersonalProtectionEquipment(PPE).
WARNING:Topreventpersonalinjuryand/ordeath,payattentiontosecondaryreevents.There
isahighriskofreignitionduetodamageandcorrosion.Saltwaterincreasesthisriskforelectrical
shortspostincident.KeepfullPersonalProtectionEquipment(PPE),includingSelf-Contained
BreathingApparatus(SCBA)ready.
WARNING:Topreventpersonalinjuryand/ordeath,avoidanycontactwithasubmerged
high-voltagesystem.DonotattempttodisabletheHigh-VoltageServiceDisconnectswitchwhilethe
vehicleissubmerged.TheignitionmaybeturnedOFF.
1.TurnthevehicleOFF(ifpossible).
2.Recoverthevehicle.
3.Drainthewateroutofthevehicle.
4.Turnthehigh-voltagedisconnectswitchtotheOFFposition.
4328810R120
©2021Navistar,Inc.Allrightsreserved.Allmarksaretrademarksoftheirrespectiveowners.