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" Insulation gloves rated at 1000V with leather protectors

- Visually and functionally inspect the gloves before use.

- Wear the Insulation 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.

Note: Use the correct procedure, depending on components being serviced, to disable the High Voltage system.

Refer to one of the following procedures below depending on components being serviced:

* When Servicing Drive Motor Generator Battery Assembly or 300 V DC Cable
* When Servicing Drive Motor Generator Control Module Assembly or Cable Connections

When Servicing Drive Motor Generator Battery Assembly or 300 V DC Cables

1. Review the high voltage safety information prior to performing the High Voltage Disabling procedure. Refer to High Voltage Safety High Voltage Safety.

Note: The 12 V battery must be disconnected to ensure proper test results.

2. Disconnect the 12 V battery. Refer to Battery Negative Cable Disconnection and Connection Battery Negative Cable Disconnection and Connection.
3. Disable the voltage sources to the 2 mode hybrid vehicle.

1. Remove the ignition key.
2. Remove the Generator Battery Cover Access Door Replacement Generator Battery Cover Access Door Replacement.
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 5 minutes before continuing, to allow the capacitors to discharge.

Note: Wear your High Voltage Insulation gloves until you have determined that a high voltage exposure risk is no longer present.

4. Remove the terminal extension cover assembly.

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

1. Set the digital multimeter (DMM) to DC mode. Verify the DMM works by measuring the voltage of the 12 V battery.
2. Using the DMM, verify the voltage measures less than 3 V at the following points:

* High voltage DC (+) positive (3) and high voltage DC (-) negative (4) terminals.
* High voltage DC (+) positive (3) to vehicle chassis ground.
* High voltage DC (-) negative (4) to vehicle chassis ground.
* High voltage manual disconnect terminal (1) to the high voltage DC positive and negative terminal connections (3, 4).
* High voltage manual disconnect terminal (2) to the high voltage DC positive and negative terminal connections (3, 4).

• If the test result was greater than 3 V, there is a stuck closed contactor and a loss of isolation within the drive motor generator battery assembly. Refer to High Voltage Contactor/Relay Malfunction High Voltage Contactor/Relay Malfunction.

6. Retest the DMM by measuring the 12 V battery.

• If the DMM does not properly measure the 12 V battery, repair or replace the DMM and repeat all voltage measurements.
• If all the test results were less than 3 V, the 300 V 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. Review the high voltage safety information prior to performing the High Voltage Disabling procedure. Refer to High Voltage Safety High Voltage Safety.

Note: Wear your High Voltage Insulation gloves until you have determined that a high voltage exposure risk is no longer present.

5. Remove the 3 phase cable cover.

6. 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 digital multimeter (DMM) to DC mode. Verify the DMM works by measuring the voltage of the 12 V battery.
2. Using the DMM, verify the voltage measures less than 3 V at the following points:

* High voltage DC (+) positive (1) and high voltage DC (-) negative (2) terminals.
* High voltage DC (+) positive (1) to vehicle chassis ground.
* High voltage DC (-) negative (2) to vehicle chassis ground.

• If the test result was greater than 3 V, there is a stuck closed contactor and a loss of isolation within the drive motor generator battery assembly. Refer to High Voltage Contactor/Relay Malfunction High Voltage Contactor/Relay Malfunction.

7. Retest the DMM by measuring the 12 V battery.

• If the DMM does not properly measure the 12 V battery, repair or replace the DMM and repeat all voltage measurements.

8. If all the test results were less than 3 V, the cables can now be removed from the drive motor generator control module assembly.