TECHNICAL SERVICE OPERATIONS

MAS003876 MCL 24-35
Circular Letter
FROM: Maserati TSO
TO: Maserati Network

Introduction to Maserati Folgore

DATE: JULY 10 2024

Maserati is an innovative brand by nature, with a unique style fuelled by inexhaustible passion. These
values inspired the Maserati brothers almost 109 years ago and are still driving us today to play a
leading role on the e-mobility world stage. With a unique blend of tradition and innovation, Maserati
is ready to launch Folgore, the new 100% electric range.

Please read and review this bulletin first before ordering parts and/or starting the procedure.
Contact your Regional AfterSales Manager (RAM) or the Technical Support Helpdesk if you have any
questions.
Thank You for your continued support and cooperation.
Maserati North America
Aftersales Dept.

© 2024 Maserati North
America. Aftersales
www.maseratiusa.com

MAS003876

All rights reserved. Reproduction or translation in
whole or in part is not permitted without
authorization from the publisher. Printed in USA

Page 1 of 23

1.

Folgore vehicle description ............................................................................................................ 3

2.

High-voltage system overview ....................................................................................................... 3

3.

Service requirements ...................................................................................................................... 7

4.

Training courses and workshop personnel .................................................................................... 8

5.

Securing the vehicle........................................................................................................................ 8

6.

Activation of the Maserati Technical Team ................................................................................... 9

7.

Warranty Conditions ........................................................................................................................ 9

7.1.

Circular Economy – Refurbished batteries ................................................................................ 9

8.

Vehicle and new spare batteries acceptance........................................................................... 10

9.

Service Process .............................................................................................................................. 12

9.1.

Safe batteries – regular service operations ............................................................................. 13

9.2.

Damaged Batteries ................................................................................................................... 13

10.

High-voltage battery management ......................................................................................... 13

10.1.

Risks linked to high voltage lithium-ion batteries. ................................................................ 13

10.2.

Battery Health and Performance. ........................................................................................ 14

10.3.

Battery maintenance and service ....................................................................................... 14

10.4.

Workshop lifts .......................................................................................................................... 14

10.5.

Battery classification and replacement ............................................................................... 16

10.6.

Battery management, general handling, and storage...................................................... 17

10.7.

Warranty claims and battery-related returns Mgmt ........................................................... 19

10.8.

Battery disposal ...................................................................................................................... 19

11.

Electric Drive Modules management ...................................................................................... 19

12.

Management of other high-voltage components .................................................................. 19

13.

High Voltage Personal Protective Equipment (PPE) ................................................................ 20

14.

Tools and equipment ................................................................................................................. 22

14.1.

Generic tools .......................................................................................................................... 22

14.2.

Special tools ........................................................................................................................... 23

© 2024 Maserati North
America. Aftersales
www.maseratiusa.com

MAS003876

All rights reserved. Reproduction or translation in
whole or in part is not permitted without
authorization from the publisher. Printed in USA

Page 2 of 23

TECHNICAL SERVICE OPERATIONS

Table Of Contents

The Maserati Folgore are 100% battery electric vehicles, also known as BEVs. They are powered by the energy
stored in the battery, which is used by the electric motors for vehicle propulsion. Differently from an internal
combustion engine that burns fossil fuels and produces polluting exhaust gases, the Folgore vehicles are zeroemission. Electric vehicles must be recharged at public charging stations or using a domestic supply network.
Due to the high power delivered by the vehicle systems, the battery is required to operate at high voltage.
Understanding the main quantities that define battery propulsion – kW (kilowatt), kWh (kilowatt-hour), and V
(voltage) – is important when dealing with BEVs.

Kilowatts (kW) Is a measure of the power involved during the recharge phase. Every recharging station
can deliver a certain amount of power. The more is the power delivered, the less is the time needed for a
complete or partial recharge.

Kilowatt-hour (kWh) Expresses the total energy that can be stored in an energy storage system, such as a
high-voltage lithium-ion battery, to guarantee a given mileage range, according to the driving style and
habits of the customer.

Voltage (V) Refers to the electrical potential of the high-voltage battery. In the automotive high values of
voltage are used to obtain high power. High voltage introduces risks for the operators that must be kept
under control. The first two Maserati BEV launch models, GranTurismo and Grecale Folgore will have different
lithium-ion battery types with different voltages (GranTurismo 800V and Grecale 400V).

2. High-voltage system overview
An electric vehicle is composed of new devices different from a traditional internal combustion engine
vehicle. A schematic overview of the main components of the Folgore vehicles architecture is shown
below:

Following a quick description of each component is offered:

•

Battery (HVBP - High-Voltage Battery Pack): The traction battery, which is used to store energy and power the
propulsion of the battery-electric vehicle (BEV), is the heart of the new Folgore range. The batteries in the
Folgore vehicles are capable of reaching high performance in terms of mileage and power.

New GranTurismo HVBP

© 2024 Maserati North
America. Aftersales
www.maseratiusa.com

Grecale HVBP

MAS003876

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whole or in part is not permitted without
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TECHNICAL SERVICE OPERATIONS

1. Folgore vehicle description

Electric Drive Module (EDM): Electric motors use the energy stored in the battery and transform it into
mechanical energy to enable the vehicle to move. Electric motors have much higher efficiencies than
internal combustion engines (~80%). Motors are designed to work with three-phase alternating currents,
and they can also recover energy during the braking phase.

New GranTurismo EDM
•

Grecale EDM

Inverter module (PIM - Power Inverter Module): Inverters are interposed between the motor and the battery
to transform the direct current stored in the battery into an alternating current used for running the EDMs.
During braking and deceleration, the PIMs transform the alternating current generated by the motor into a
direct current to be stored in the battery.

New GranTurismo PIM

•

Grecale PIM

Electric A/C Compressor (EAC): Air conditioning is not only for comfort purposes but it is also used to cool the
battery. Rather than being moved by the accessory belt it is powered by an embedded electric motor.

New GranTurismo EAC

•

Grecale EAC

Electric Coolant Heater (ECH): In very cold weather, the electric heater comes into play to heat the
passenger compartment and the traction battery. The battery must always be in a well-defined
temperature range to operate correctly.

New GranTurismo ECH

© 2024 Maserati North
America. Aftersales
www.maseratiusa.com

Grecale ECH1 & ECH2

MAS003876

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whole or in part is not permitted without
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Page 4 of 23

TECHNICAL SERVICE OPERATIONS

•

TECHNICAL SERVICE OPERATIONS

Auxiliary Power Module (APM): Compared to internal combustion engine vehicles on which the alternator
charges the 12V battery, on the Folgore vehicles this is performed by the APM that charges the 12V battery
by getting energy from the high-voltage battery.

New GranTurismo APM

Grecale APM

•

Ground Straps: every high-voltage device in the vehicle is provided with a ground strap that protects
operators from possible high-voltage current circulating on the device chassis. Every strap is fastened to the
device and the vehicle chassis using screws: when removed during service operations, special attention
must be paid during refit installation: the torque prescribed in the Technical Documentation must be used
to ensure the proper electrical continuity between the device and the chassis.

•

Charging sockets (AC + DC): The battery is recharged using an external source of electrical energy,
transmitted to the vehicle using a charging cable. The vehicle can be charged at various power values
both with AC stations and DC stations. In particular, the Folgore can be charged up to 22 kW in AC and
up to 270 kW in DC. A picture of the charging ports in use is shown below:

The use of an adapter is required for the Japanese market. It must be interposed between the charging station
plug and the charging port of the vehicle.

•

On-Board Charger Module (OBCM): It is the high-voltage AC/DC converter, it converts AC from the electric
grid into high-voltage DC to charge the battery pack. It only works for AC charging.

© 2024 Maserati North
America. Aftersales
www.maseratiusa.com

MAS003876

All rights reserved. Reproduction or translation in
whole or in part is not permitted without
authorization from the publisher. Printed in USA

Page 5 of 23

•

TECHNICAL SERVICE OPERATIONS

New GranTurismo OBCM

Grecale OBCM

DC Booster (DCBC): the DCBC (only for the GranTurismo Folgore) is necessary to step up the voltage of
the 400V charging station to 800V as required by the battery system.

New GranTurismo DCBC

•

High-voltage electrical wiring: The high-voltage electrical wiring is orange colored to distinguish it from
other wiring present in the vehicle.

•

12 V battery: As on conventional internal combustion engine vehicles, the 12 V battery powers all the
devices of the vehicle, including the starting, control, and safety systems. The 12V battery is recharged
by the high-voltage battery via a periodic charge level monitoring system. The charging strategies of
the 12V battery from the high-voltage battery depend on the charge level of the latter. If the charge
level of the high-voltage battery falls below a threshold limit, this process will be inhibited and the 12V
battery will no longer be charged. In the specific case of a discharged 12V battery that can no longer
be recharged via the high-voltage battery, it will no longer be possible to charge the high-voltage
battery or even start the vehicle. In this eventuality, an external 12V power source will be needed to
start the charging phase and restore normal vehicle functionality.

© 2024 Maserati North
America. Aftersales
www.maseratiusa.com

MAS003876

All rights reserved. Reproduction or translation in
whole or in part is not permitted without
authorization from the publisher. Printed in USA

Page 6 of 23

Authorized Maserati workshops will have to meet minimum requirements to be able to deal with Folgore
vehicles. An outdoor acceptance area, a quarantine area, and a sufficient workspace for battery handling
during service operations are required. Furthermore, personnel must be appropriately trained on the risks of
managing high-voltage vehicles and qualified to operate according to the respective local regulations. An
overview of the minimum requirements is shown below:
Outdoor Acceptance Area: Folgore vehicles and spare new batteries must be received in an outdoor area,
adjacent to the workshop, to run the initial checks on the condition of the vehicle and the HV system. This area
ensures that initial inspections of the entire high-voltage system can be carried out safely, preventing risks inside
the workshop. Details on the checks to be performed will be published in the Technical Documentation (Modis
CS+), and the Whitebook AS Tools will be updated accordingly and can be found in this communication (refer
to Chapter 8).
Quarantine Area: In the event of malfunctions or critical damage to the high-voltage battery, the vehicle or the
battery must be moved to a dedicated area. The area must be outdoors, provide appropriate shelter for the
vehicle/battery from the weathering, and allow to keep the vehicle/battery away from other vehicles,
structures, or flammable components (fig. 4.1). Furthermore, the area around the vehicle must be cordoned off
with chains and poles. Signs must be put up to indicate that the vehicle/battery is dangerous and access by
unauthorized personnel is prohibited. The floor of the quarantine area must prevent any leakage of substances
from the battery from being drained by the ground. Refer to the local regulations in force to adapt fire
protection systems for managing high-voltage lithium-ion batteries. For more detailed information, refer to the
Maserati service guidelines.

Figure 4.1: A= distance from unauthorised personnel.
B= distance from other vehicles, structures, or flammable components.
Staff training: The following training is mandatory to be able to manage all aspects of the new Folgore Maserati
vehicles and to be able to access the Academy training courses.
1.

The dealer/employer is responsible for providing occupational safety certification in compliance with local
laws to work on battery electric vehicles (BEVs), high-voltage systems, and lithium-ion batteries, and is also a
prerequisite for personnel to participate in the Maserati Academy Aftersales training on electric
vehicles/lithium-ion batteries.

2. Academic training on electric vehicles is mandatory for the following activities:
•

sales, acceptance, servicing, repair, storage/logistics management of Maserati electric vehicles

•

storage, handling, and securing of Maserati lithium batteries.

Defective batteries that are uninstalled from the vehicle, as explained later in detail, must be returned to
Maserati. For dangerous goods (high-voltage batteries) transportation return, the sender must be trained by
attending a specific training course, not provided by Maserati, after which a certificate is issued to ensure
compliance with transportation regulations (checking package conformity, affixing the mandatory labels and
issuing the necessary documents that accompanies the package). The transportation regulations (e.g., ADR or
IMDG) also make specific reference to the “loader” and the destination warehouse. The destination warehouse
is responsible for unloading the goods at the destination checking that all provisions have been complied with
by the sender and reporting anomalies if necessary. The courses are organized by legally qualified certified
agencies and a certificate is issued to attendees at the end.
© 2024 Maserati North
America. Aftersales
www.maseratiusa.com

MAS003876

All rights reserved. Reproduction or translation in
whole or in part is not permitted without
authorization from the publisher. Printed in USA

Page 7 of 23

TECHNICAL SERVICE OPERATIONS

3. Service requirements

Training courses and workshop personnel

Training courses delivered by Maserati Academy to workshop technicians will be specific to Maserati products
and will have a particular focus on how to manage vehicles with high-voltage (HV) systems safely. Many
countries require specific certification for workers who manage the high-voltage system of battery electric
vehicles (BEVs). The employer is always responsible for complying with local law regarding the training and
certification of its personnel working on these systems. It is important to note that Maserati, as an OEM, will not
provide such training or certification for dealership personnel.

For this reason, starting in 2023, Maserati will identify workshop technicians as follows:

•

EV Specialist: This label will be added in the HR section in Dealer Intelligence (DI) to identify workshop
technicians who are qualified to work on high-voltage systems (active or not) according to the
certifications required by local laws provided by the dealership. Each dealership is required to identify at
least one workshop technician as an EV Specialist (however, it is recommended to identify two
technicians). The identified EV Specialists will be involved in specific training on the management of HV
systems on Maserati Folgore vehicles.

•

All other workshop technicians: Technicians not qualified to work on active high-voltage systems will be
involved in technical training on Folgore products. This training program will include a technical
presentation of the Folgore product and awareness of the potential safety risks of HV systems but will not
include specific operations on active HV systems on Maserati vehicles.

Therefore, to participate in the training courses, it will be necessary to update the HR section on Dealer
Intelligence to specify which of your workshop technicians will be EV Specialists and tick the box for training selfcertification following local law.
Assigning at least one workshop technician as an EV Specialist is a mandatory requirement for the certification
of the E-Mobility standards for Folgore vehicles.

5. Securing the vehicle
The high-voltage system must be disabled to carry out repair work on high-voltage components or
work involving possible contact with high-voltage components on Folgore vehicles. In the event of