High Voltage Disabling

High Voltage Disabling

Danger: Ensure all High Voltage safety procedures are followed. Failure to follow the procedure exactly as written may result in serious injury or death.

Danger: Before working on any high voltage system, be sure to wear the following Personal Protection Equipment:

* Safety glasses with appropriate side shields when within 50 feet of the vehicle, either indoors or outdoors

* Certified and up-to-date Class "0" isolation gloves rated at 1000V with leather protectors

- Visually and functionally inspect the gloves before use.

- Wear the isolation gloves at all times when working with the high voltage battery assembly, whether the system is energized or not.

* Failure to follow the procedure exactly as written may result in serious injury or death.

Servicing Drive Motor Generator Battery Assembly or 300V DC Cables




1. Review the high voltage safety information prior to performing the High Voltage Disabling procedure. Refer to High Voltage Safety.
2. Disable the voltage sources to the 2 mode hybrid vehicle.

1. Remove the ignition key.
2. Remove the right side drive motor generator battery assembly close out panel.
3. Remove the high voltage manual disconnect lever. Attach the ignition key to the lever and put the lever and the ignition key in a secure place.

^ Wait at least 5 minutes before continuing, to allow the capacitors to discharge.

Important: The 12 volt battery must be disconnected to ensure proper test results.

3. Disconnect the 12 volt battery.
4. Remove the drive motor generator battery assembly trim cover.




5. Remove the terminal extension cover assembly.




6. To verify that the voltage has been disabled at the drive motor generator battery assembly terminals, perform the following:

1. Set the voltmeter to DC mode. Verify the voltmeter works by measuring the voltage of the 12 volt battery.
2. Using the voltmeter, verify the voltage measures less than 3 volts at the following points:

* Across the HVDC (+) positive (3) and HVDC (-) negative (4) terminals

^ If the test result was more than 3 volts, the drive motor generator control module internal capacitors are still charged. Keep the isolation gloves on and install the cable cover. Wait 5 minutes and then remove the cover and return to the beginning of this step.

* HVDC (+) positive (3) to vehicle chassis ground
* HVDC (-) negative (4) to vehicle chassis ground

^ If the test result was more than 3 volts, there is a stuck closed contactor and a loss of isolation within the drive motor generator battery assembly. Refer to High Voltage Contactor Relay Always Closed. High Voltage Contactor Relay Always Closed

7. Using a DMM test for voltage from the High Voltage manual disconnect terminal A (1) to the High Voltage DC positive and negative terminal connections (3, 4). The result should be less than 3 volts.

^ If the test result was more than 3 volts, a high voltage contactor is stuck closed. Refer to High Voltage Contactor Relay Always Closed. High Voltage Contactor Relay Always Closed

8. Using a DMM test for voltage from the High Voltage manual disconnect terminal B (2) to the high voltage DC positive and negative terminal connections (3, 4). The result should be less than 3 volts.

^ If the test result was more than 3 volts, a high voltage contactor is stuck closed. Refer to High Voltage Contactor Relay Always Closed. High Voltage Contactor Relay Always Closed

9. Retest the voltmeter by measuring the 12 volt battery.

^ If the voltmeter does not properly measure the 12 volt battery, repair or replace the voltmeter and repeat all voltage measurements.
^ If all the test results were less than 3 volts, the 300V DC cables can now be removed from the drive motor generator battery assembly.

When Servicing Drive Motor Generator Control Module Assembly or Cable Connections

1. Disable the voltage sources to the 2 mode hybrid vehicle.

1. Remove the ignition key.
2. Remove the right side drive motor generator battery assembly close out panel.
3. Remove the high voltage manual disconnect lever. Attach the ignition key to the lever and put the lever and the ignition key in a secure place.

^ Wait at least 5 minutes before continuing, to allow the capacitors to discharge.

Important: The 12 volt battery must be disconnected to ensure proper test results.

2. Disconnect the 12 volt battery.
3. Remove the drive motor generator control module sight shield.




4. Remove the 3 phase cable cover.




5. To verify that no voltage is present at the high voltage connection for the drive motor generator control module, perform the following:

1. Set the voltmeter to DC mode. Verify the voltmeter works by measuring the voltage of the 12 volt battery.
2. Using the voltmeter, verify the voltage measures less than 3 volts at the following points:

* Across the HVDC (+) positive (1) and HVDC (-) negative (2) terminals

^ If the test result was more than 3 volts, the drive motor generator control module internal capacitors are still charged. Keep the isolation gloves on and install the cable cover. Wait 5 minutes and then remove the cover and return to the beginning of this step.

* HVDC (+) positive (1) to vehicle chassis ground
* HVDC (-) negative (2) to vehicle chassis ground

^ If the test result was more than 3 volts, the capacitors have remained charged and a loss of isolation condition is present. Keep the isolation gloves on and install the cable cover. Wait 5 minutes and then remove the cover and return to the beginning of this step.

6. Retest the voltmeter by measuring the 12 volt battery.

^ If the voltmeter does not properly measure the 12 volt battery, repair or replace the voltmeter and repeat all voltage measurements.
^ If all the test results were less than 3 volts, the cables can now be removed from the drive motor generator control module assembly.