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Procedures




Drive Motor Battery Replacement and Shipping Preparation

Special Tool
* EL-48265 - Battery Lifting Fixture
* EL-48569 - Terminal Covers

For equivalent regional tools, refer to Special Tools Tools and Equipment.

Removal Procedure

Danger: Always perform the High Voltage Disabling procedure prior to servicing any High Voltage component or connection. Personal Protection Equipment (PPE) and proper procedures must be followed.


The High Voltage Disabling procedure will perform the following tasks:


* Identify how to disable high voltage.

* Identify how to test for the presence of high voltage.

* Identify condition under which high voltage is always present and personal protection equipment (PPE) and proper procedures must be followed.


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





1. Disable the high voltage at both the drive motor generator battery assembly and the drive motor generator control module assembly. Refer to High Voltage Disabling High Voltage Disabling.
2. Remove the high voltage terminal extension cover. Refer to Drive Motor Battery Cable Terminal Extension Cover Replacement Drive Motor Battery Cable Terminal Extension Cover Replacement
3. Remove the battery cable terminal fasteners (1) and reposition the cable terminals.






Warning

High Voltage (HV) cables are not repairable. After disconnecting HV cables, protect and insulate ring terminal ends immediately with the EL-48569 terminal covers and UL(R) Listed, or equivalent, insulation tape rated at a minimum of 600 volts. Damage caused to unprotected terminal ends will result in cable replacement.

4. Using the EL-48569 - covers , cover the 300 Volt positive and negative terminals (2).




5. Disconnect the retaining clips (1) and remove the battery vent tube (2).




6. Remove the air outlet duct retainer (1) and the air outlet duct (2).




7. Remove the generator battery retaining nuts (1).





Caution: Refer to Fastener Caution Fastener Caution.

8. Install the drive motor battery cable terminal extension cover (1) and bolts (2) and tighten to 6 Nm (53 lb in).
9. Disconnect the X350 harness connector from the drive motor generator battery.




10. Using the EL-48265 - fixture , secure the drive motor battery at the lifting points (1).





Danger: The high voltage (HV) battery must be protected when outside of the vehicle.


Storage Guidelines


* Store the HV battery flat, do not exceed 45 degrees when handling.

* Store the HV battery in an environmentally protected area.

* Maintain the HV battery at room temperature.

* Protect the HV battery from exposure to liquids.

* Protect the HV battery from physical damage.


Unqualified Access Guidelines


1. Cover all exposed high voltage openings with UL(R) listed, or equivalent, insulation tape rated at a minimum of 600 volts.

2. Store the HV battery in a limited-access area.


Failure to follow these guidelines may result in serious injury or death.


Note: If preparing the drive motor generator battery for shipment, Install the terminal extension cover assembly and retaining bolts. Using UL(R) listed or equivalent insulation tape, rated at a minimum of 600 V, tape over the manual disconnect opening and the high voltage cable openings on the terminal extension cover.

11. Remove the drive motor generator battery assembly (1).

Installation Procedure




1. Using the EL-48265 - fixture , secure the NEW drive motor battery at the lifting points (1).





Danger: The high voltage (HV) battery must be protected when outside of the vehicle.


Storage Guidelines


* Store the HV battery flat, do not exceed 45 degrees when handling.

* Store the HV battery in an environmentally protected area.

* Maintain the HV battery at room temperature.

* Protect the HV battery from exposure to liquids.

* Protect the HV battery from physical damage.


Unqualified Access Guidelines


1. Cover all exposed high voltage openings with UL(R) listed, or equivalent, insulation tape rated at a minimum of 600 volts.

2. Store the HV battery in a limited-access area.


Failure to follow these guidelines may result in serious injury or death.


2. Install the drive motor generator battery assembly (1).
3. Connect the X350 harness connector from the drive motor generator battery.





Caution: Refer to Fastener Caution Fastener Caution.

4. Install the generator battery retaining nuts (1) and tighten to 50 Nm (37 lb ft).




5. Install the air outlet duct (2) and the air outlet duct retainer (1).




6. Connect the battery vent tube (2) and retaining clips (1).




7. Remove the EL-48569 - covers , from the 300 Volt positive and negative terminals (2).




8. Reposition the cable terminals and Install the battery cable terminal fasteners (1) and tighten to 9 Nm (80 lb in).
9. Install the high voltage terminal extension cover. Refer to Drive Motor Battery Cable Terminal Extension Cover Replacement Drive Motor Battery Cable Terminal Extension Cover Replacement.
10. Enable the high voltage system. Refer to High Voltage Enabling High Voltage Enabling.
11. After replacing the battery pack, check for the latest software calibration. Refer to service programing system, Service Programming System (SPS) Service Programming System (SPS).

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