Renault ZOE 2013 User manual

Renault ZOE - Roadside assistance technician's guide
RENAULT PROPERTY
Network Development | Version 2.1 | 11 January, 2013
1
RENAULT ZOE
Series produced electric vehicle
Roadside assistance
technician's guide

Renault ZOE - Roadside assistance technician's guide
RENAULT PROPERTY
Network Development | Version 2.1 | 11 January, 2013
2
Introduction
•This guide is intended to inform roadside assistance technicians who have to tow a vehicle or
perform repairs on the spot. It contains the instructions and precautions to be followed when working
on a ZOE that has broken down or has been involved in an accident.
•This guide refers to MR* 457 for all the repair methods applicable to the electric parts of ZOE. MR
457 is available in DIALOGYS or in the Renault technical information document database,
INFOTECH, at: http://www.infotech.renault.com
*MR = repair method
It is necessary to read this guide and the repair methods described in MR 457 in order to
understand the specifics of this vehicle and avoid the risk of injury or electric shock when working
on the vehicle.
ZOE is driven exclusively by an electric motor. The electric power is stored in a rechargeable traction
battery. ZOE uses both a 400V high-voltage and a 12V very low-voltage system.
Electric safety is an important factor when working on ZOE. As for all products that use both a high-voltage
and a very low-voltage system, it is imperative to follow the specific procedures when working on them. It is
necessary to be capable of understanding ZOE and to be familiar with and applying the safety procedures
and alerts contained in this guide.
A ZOE vehicle that has been involved in an accident or has broken down must be towed by
a qualified recovery-repair technician who is authorised to work on the onboard high-
voltage network on electric vehicles.
Important lessons in terms of safety and speed and quality of repairs can be learnt by taking the time to
read these documents, in order to:
!prevent major mechanical and/or electrical damage during recovery
!fully understand the towing methods that are possible and permitted
!comply with the recovery conditions defined by national legislation
!comply with the recovery vehicle's payload.
!act in a way that guarantees the safety of the occupants of the immobilised vehicle.
This guide contains useful and relevant information that will allow roadside assistance technicians to:
•recognise the vehicle model type in the Renault group range,
•understand its salient technical features,
•identify the risks inherent in the onboard technologies and adapt their repair tools and methods in order
to intervene in complete safety.

Renault ZOE - Roadside assistance technician's guide
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Network Development | Version 2.1 | 11 January, 2013
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Contents
1. Identification of the ZOE vehicle..............................................................................................4
a. External identifying characteristics........................................................................................................4
b. Identifying features in the cab ...............................................................................................................6
c. Identifying features in the engine compartment ....................................................................................7
2. Technical description of ZOE...................................................................................................7
a. Traction chain and 400V electric circuit ................................................................................................7
b. Vehicle underbody ................................................................................................................................8
c. 12V battery............................................................................................................................................8
d. 400 V traction battery............................................................................................................................9
e. Energy transfer and isolation of the 400V circuit.................................................................................10
3. What to do when a ZOE vehicle is submerged in water......................................................11
a. Case of a submerged vehicle:.............................................................................................................11
b. Securing the vehicle after it has been removed from the water. .........................................................11
4. Working on a ZOE vehicle damaged by fire .........................................................................13
a. Risks and protective equipment ..........................................................................................................13
5. Procedure to tow a ZOE vehicle that has been involved in an accident...........................13
a. Individual protective equipment for repairs .........................................................................................14
b. Risks and procedures before working on a ZOE vehicle that has been involved in an accident ........15
c. What to do in the event of an electrolyte leak from the 400V traction battery.....................................16
d. Immobilising the vehicle ......................................................................................................................16
e. Disconnecting a ZOE vehicle involved in an accident when charging ................................................17
f. 400V circuit lockout .............................................................................................................................19
g. Opening the bonnet.............................................................................................................................19
h. Locking out the 12 V battery ...............................................................................................................20
i. External and internal signs for the various operations ........................................................................22
1. "Caution - Danger" sign on ZOE......................................................................................................22
2. "Secure vehicle" sign on ZOE .........................................................................................................23
3. Lockout-tagout sheet for ZOE. ........................................................................................................24
j. Accessing the anchor points of the tow rings......................................................................................25
k. Manually releasing the gear selector ..................................................................................................25
l. Manually releasing the steering column..............................................................................................25
m. Authorised/unauthorised towing of a ZOE that has been involved in an accident...........................26
n. Securing the vehicle............................................................................................................................27
6. Towing and/or recovering a broken down ZOE ...................................................................27
a. Types of repairs prohibited on the roadside........................................................................................27
b. Authorised/unauthorised towing of a broken down ZOE, including further to a power failure.............28
7. Reminder: technical instructions for transport on flatbeds ...............................................29
a. Loading the ZOE that has been damaged in an accident or has broken down on a flatbed...............29
b. Lashing ZOE onto a flatbed ................................................................................................................30
o. Loading a broken down ZOE on a tow dolly type vehicle. ..................................................................32
p. Lashing ZOE onto a tow dolly type vehicle .........................................................................................33
8. Equipment, tools and spare parts to be kept in the recovery and / or assistance vehicle34
9. Storing a ZOE electric vehicle in a dealership .....................................................................36
a. Marking out the storage zone:.............................................................................................................36
oDefinition of the surface area for the storage of electric vehicles damaged in an accident: ...............36
oSafety information ...............................................................................................................................37
10. Towing decision tree flow chart.............................................................................................38
a. Flow chart 1 – assistance officer in the call centre or the RENAULT dealership ................................38
b. Flow chart 2 – Roadside assistance technician – Vehicle broken down.............................................39
c. Flow chart 3 – Roadside assistance technician – Vehicle damaged in an accident ...........................40

Renault ZOE - Roadside assistance technician's guide
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1. Identification of the ZOE vehicle
"Only an electric version of this vehicle exists.
"Electric vehicles can be identified by the absence of an exhaust pipe and a fuel filler flap.
a. External identifying characteristics
Front view:
Main criteria:
#Blue chrome logo at the front
$Charging flap under the logo
Secondary criteria:
%Comma-shaped LED in the bumper
&Blue chrome surround on the air inlet
Charging flap closed
Charging flap open

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Main criteria:
#Z.E. badge
$Specific blue rear lights with
internal diamond-shaped mask
%Blue chrome rear diamond
Secondary criteria:
&Absence of an exhaust pipe
'No fuel filler flap on the rear wing
Side and rear view:
5
4
2
3
1
5

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b. Identifying features in the cab
Passenger compartment view:
#Z.E. pictogram on the gear
lever
$Blue chrome logo on the
steering wheel
3Printed circuits on the
dashboard and the ceiling trim
On the dashboard:
1
2
3
Specific controls for electric vehicle

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c. Identifying features in the engine compartment
Engine compartment:
#Specific stickers on the
accessible 400V
components
$Orange 400V cables
"The fact that the 400V cables are orange does not means that they are fire-proof
2. Technical description of ZOE
a. Traction chain and 400V electric circuit
1Electric charge port
behind the logo
2Electric motor
3Orange 400V cables
and connection zone
between the cables and
the traction battery
4Traction battery

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b. Vehicle underbody
#Traction battery
$Connection between the
orange 400V cables and the
traction battery, protected by a
casing (the casing was
removed for the photo)
%Aerodynamic casing
c. 12V battery
The electric vehicle's 12V battery is a 12V DC secondary battery. It supplies the energy required for the
vehicle's equipment (lights, wipers, sound system, etc.) and certain safety systems, such as the power
brakes.
The installation and removal procedure for the 12V battery in the ZOE electric vehicle is
described in Chapter 80A in MR 457.
MR 457 is available in DIALOGYS or in the Renault technical information document
database, INFOTECH, at: http://www.infotech.renault.com
"This 12V battery can be replaced with an equivalent battery whenever
necessary.
"It is located in the engine compartment at the front of the vehicle. The
negative terminal is connected to the metallic chassis to create an electric
earth.
"Reminder: this operation must be performed by a qualified recovery and repair
technician who is qualified to work on the onboard high-voltage network in
electric vehicles.
"RISK OF SERIOUS INJURY OR ELECTRIC SHOCK WHICH MAY RESULT IN
DEATH.

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Specifications of the 12 V battery
Voltage 12 V
Current intensity 70 A
Battery type Lead
Model L3 standard
d. 400 V traction battery
Specifications of the traction battery
Voltage 400 V
Current intensity 300 A
Capacity 26 kWh
Weight 290 Kg
Battery type Lithium-ion
Dimensions (L*w*h) 1280 * 1630 *335
"The vehicle's traction battery must only be removed in quick-exchange
stations or approved garages.
"RISK OF SERIOUS INJURY OR ELECTRIC SHOCK WHICH MAY RESULT IN
DEATH.
#Traction battery
$Traction battery cutout
%Air inlets/outlets of the
traction battery cooling
system (may be closed,
depending on the version)
&Connection zone
between the battery and
the motor

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e. Energy transfer and isolation of the 400V circuit
All the 400V cables are ORANGE for identification purposes.
The 400V circuit is isolated from the vehicle's metal chassis.
The parts of the 400V circuit are electrically grounded on the vehicle (e.g. by grounding braids, etc.). These
connections protect the vehicle's occupants and the emergency services against electric shocks.
Orange 400V cable Earth strap
"Never cut the orange 400V cables.
"Never cut the grounding braids.
"These grounding connections protect the vehicle's occupants and the
emergency services against the risk of electric shocks.
"RISK OF SERIOUS INJURY OR ELECTRIC SHOCK WHICH MAY RESULT IN
DEATH.

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3. What to do when a ZOE vehicle is submerged in water
a. Case of a submerged vehicle:
For an electric vehicle, the reference of the electrical energy is the negative terminal of the traction battery.
The risk of electrifying only exists if a person comes into contact with the two electrical terminals of a circuit
supplied by the traction battery. There is therefore no danger involved in touching the water and the body of
the submerged vehicle.
The victims of an accident can be rescued, even if the vehicle is still in contact with the water.
"As a precautionary measure, when working on a vehicle that is totally or
partly submerged, and in humid environments in general, do not directly
touch the orange 400V cables, the 400V components, the traction battery
circuit breaker or the traction battery.
"RISK OF SERIOUS INJURY OR ELECTRIC SHOCK WHICH MAY RESULT IN
DEATH.
b. Securing the vehicle after it has been removed from the water.
Recovery sequence
WARNING:
The vehicle can only be made safe once it has been taken out of the water.
Always obey the following recommendations when working in humid
environments.
"Once the vehicle has been taken out of the water, it is imperative to make
the vehicle electrically safe in order to avoid the risk of further accidents in
the logistics chain (recovery, storage).
"Since certain consumers of electric power may still be active, disconnecting
the 12V battery may cause serious electric arcs. Take great care when
performing this operation.

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•Leave the vehicle until all the water has flowed out of the cab.
•Always wear electric protective gloves and a face screen.
•Switch the ignition off.(page 16: Immobilising the vehicle)
•Open the flap that protects the safety circuit breaker of the traction battery and remove the
safety circuit breaker from the traction battery.
oThe procedures applying to the opening of the safety circuit breaker flap and
the removal of the safety circuit breaker from the traction battery are described
in MR 457, chapter 01D.
•Close the flap protecting the safety circuit breaker of the traction battery.
•Disconnect the 12V battery
oThe procedure for the disconnection of the 12V battery is described in MR 457,
chapter 01D.
MR 457 is available in DIALOGYS or in the Renault technical information document
database, INFOTECH, at: http://www.infotech.renault.com
"Only qualified recovery and repair technicians who are authorised to work on the
high-voltage systems in electric vehicles are permitted to remove the 400V circuit
breaker and to lock out the 12V battery.
"Always wear isolating gloves and a face screen when extracting the safety circuit
breaker of the traction battery from a vehicle that has been
submerged.
"TAKE GREAT CARE! Avoid any skin contact with the water flowing
out of the traction battery when extracting the safety circuit breaker.
"RISK OF SERIOUS INJURY OR ELECTRIC SHOCK WHICH MAY
RESULT IN DEATH.

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4. Working on a ZOE vehicle damaged by fire
"The procedures indicated in this chapter must be applied when handling a
vehicle damaged by fire.
"A vehicle in which the traction battery is smoking can quickly take fire. In
this case, call the fire service immediately, specifying that the vehicle
involved is an electric vehicle then stand away from the vehicle and wait for
the emergency services to arrive.
a. Risks and protective equipment
The vehicle may still present electrical risks after the fire, due to the presence of bare live parts.
"NEVER TOUCH the damaged orange 400V cables or damaged 400V
components with your bare hands.
"RISK OF SERIOUS INJURY OR ELECTRIC SHOCK WHICH MAY RESULT IN
DEATH.
"If you have to touch the damaged orange 400V cables or the
400V components, then always wear electric protective gloves and a face
screen.
5. Procedure to tow a ZOE vehicle that has been involved in an
accident
Always wear protective equipment when working on an electric vehicle
that has been involved in an accident

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a. Individual protective equipment for repairs
For any operation on a vehicle which has been damaged in an accident, the following must be worn:
•a face shield,
•electrical safety gloves of the correct size.
Electrical safety gloves
Insulating gloves for electrical work, class 00, test voltage 2500V,
operating voltage 500V.
Class III personal protective equipment, in accordance with the
following standards:
European: EN 60 903
International: CEI 60 903
Front screen
Protects the face against projections of liquid/solid and
short circuit electric arcs.
Personal protective equipment in accordance with European
standards:
EN 166: personal eye protection, specification.
EN 170: personal eye protection, UV filter.
No-voltage tester (NVT)
The absence of voltage is measured using a measuring instrument.
No-voltage tester (NVT)
The measurement is made between the metal chassis of the
and the conducting core of the damaged orange 400V cables.
This device must comply with the following standards:
European: EN 61 243-3
International: CEI 61 243-3

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b. Risks and procedures before working on a ZOE vehicle that has
been involved in an accident
"Reminder: ZOE must only be towed by a qualified recovery and repair technician
who is qualified to work on the onboard high-voltage network in electric vehicles.
"Put on high-visibility clothing before leaving the breakdown vehicle
"Electrical safety gloves and a face shield must be worn when working
on the 400V circuit.
"Do not touch the orange 400V cables or the 400V components if they are
damaged, without the use of electrical safety equipment. A damaged component
or cable on the 400V circuit may result in burns or electrocution caused by
electric shock.
"If the safety circuit breaker of the traction battery is damaged, do not
remove and close the flap. Risks of electric shock that can cause death.
"Make sure no-one is in the immediate vicinity of the vehicle involved in the
accident
"Make sure the driver and passengers are in a safe place (e.g. behind safety
barriers)
"Identify and immobilise the vehicle (see pages 4 and 16).
"To prevent the vehicle from starting unexpectedly and causing injury,
disable (ON/OFF) the programmed pre-conditioning functions and the
automatic remote controls with the vehicle's card or key (drive train,
heating or air conditioning) before proceeding with the repairs.
"Disconnect all external power sources (e.g., charge cable, see page 17).
"Disconnect the vehicle's electric circuits before working on a vehicle that has
been involved in an accident (see pages 17 to 21).
"The repair procedures applying to power sources are described in MR 457,
available in DIALOGYS or in the Renault technical information document
database, INFOTECH, at: http://www.infotech.renault.com
"Give notice of the electric dangers "ELECTRICALLY SAFE VEHICLE" (see page
22 to 23).
"If the traction battery is damaged, there is still a fire risk that requires the
vehicle to remain under surveillance after the repairs, all along the logistics chain
(towing, storage, etc.).

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c. What to do in the event of an electrolyte leak from the 400V
traction battery
It is quite improbable that electrolyte will leak out of the traction battery. However, if an electrolyte leak does
occur, wear chemical safety gloves to protect against corrosion. Distribute absorbent products and collect
them for treatment using classic organic solvents.
The electrolyte in the lithium-ion traction battery is an inflammable and clear liquid:
"It smells like an organic solvent. Do not breathe the fumes. If a leak occurs, ventilate the
premises.
"Contact with the electrolyte will cause severe burns to the skin and eyes.
"In case of ingestion, inhalation or contact with the skin or eyes, wash with plenty of water as
soon as possible and call a poison centre or a doctor.
d. Immobilising the vehicle
"A stationary electric vehicle is silent. The motor may be on and could potentially cause
the vehicle to move.
"Only by switching off the vehicle's ignition can you be sure that the drive train has
stopped.
Procedure:
Apply the handbrake
Switch off the ignition by
pressing " START STOP"
on the right of the
steering wheel $
then remove the starter
card, if it is in the slot at
the base of the central
console. %

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Set the gear selector
to "P", Park. The
driving wheels are
now mechanically
locked.
To manually release
the gear selector, see
page 25.
e. Disconnecting a ZOE vehicle involved in an accident when
charging
ZOE can be charged at charge points using a standard charging cable. It is charged at 230V single-phase
or 400V three-phase, for a charging power of between 3kW and 43kW.
Charging diagram
1Electric power take-off
2Top-up charge cable
3Special wall unit or charge point

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1Standard top-up charge cable 2Top-up charge cable for occasional use
(availability depends on the vehicle version)
Procedure:
a. Wear gloves and a face screen.
b. If possible, disconnect the power supply from which the vehicle is being charged.
c. Disconnect the top-up charge cable from the electric power supply.
d. If the cable cannot be disconnected from the electric power supply, then disconnect it from the vehicle.
"Electrical safety gloves and face shield must be worn when
disconnecting a charging vehicle as part of this procedure.
"The main power supply must be cut, if possible, before any work is carried
out.
"Do not cut the charging lead.
"RISK OF SERIOUS INJURY OR ELECTRIC SHOCK WHICH MAY RESULT IN
DEATH.
"If the traction battery is damaged, there is a delayed risk of fire. In this case, it is
necessary to keep the vehicle or the damaged battery surveillance in a dedicated,
secure storage zone so as to prevent any outbreak of fire.
"When the vehicle is locked, an actuator prevents the charge plug from being
removed on the vehicle side. It is possible, though difficult, to pull the plug out. This
operation does not involve any risks of further accidents, even in humid
environments, as long as you wear electric protective gloves and a face
screen .

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f. 400V circuit lockout
The lockout-tagout procedure for the 400V battery in the ZOE electric vehicle is described in
Chapter 01D in MR 457.
MR 457 is available in DIALOGYS or in the Renault technical information document database,
INFOTECH, at: http://www.infotech.renault.com HYPERLINK
"https://noumea.renault.fr/owa/redir.aspx?C=8b05459b49dd41d5b07d7603629a839d&URL=http%3a
%2f%2fwww.infotech.renault.com%2f" \t "_blank"
g. Opening the bonnet
The bonnet is opened in the same way as on an internal combustion vehicle.
11
Bonnet release in the
cab, under the steering wheel on the left.
Bonnet opening handle on the right of the logo#.
Move the handle sideways.
"Reminder: this operation must be performed by a qualified recovery and
repair technician who is qualified to work on the onboard high-voltage
network in electric vehicles.
"Wear electrical safety gloves and a face shield .
"Install a "Caution. Danger" sign.

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h. Locking out the 12 V battery
The procedure to lock out the 12V battery is not identical to the procedure used on internal
combustion vehicles.
The lockout-tagout procedure for the 12V battery in the ZOE electric vehicle is described in Chapter
01D in MR 457.
MR 457 is available in DIALOGYS or in the Renault technical information document database,
INFOTECH, at: http://www.infotech.renault.com
Locating the 12V battery:
"Reminder: this operation must be performed by a qualified recovery and
repair technician who is qualified to work on the onboard high-voltage
network in electric vehicles.
"Wear electrical safety gloves and a face shield .
"Since certain consumers of electric power may still be active,
disconnecting the 12V battery may cause serious electric arcs.
Take great care when performing this operation.