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. Ignition OFF, disable the high voltage at the drive motor generator battery. Refer to High Voltage Disabling ().
2. Connect the 12 V battery.
Note: The following tests require wearing personal protection equipment (PPE) gloves.
3. Ignition ON, engine OFF, command the high voltage negative contactor closed with a scan tool. Test for less than 0.5 ohm between the high
voltage negative contactor terminals X2 and X3.
锟斤拷If greater than the specified range, replace the negative contactor relay.
4. Command the high voltage positive contactor closed with a scan tool. Test for less than 0.5 ohm between the high voltage positive contactor
terminals X2 and X3.
锟斤拷If greater than the specified range, replace the positive contactor relay.
5. Ignition OFF, test for less than 5 ohm between the high voltage negative contactor terminal X2 and the drive motor generator battery negative
terminal.
锟斤拷If greater than the specified range, replace the drive motor negative relay cable.
6. Test for less than 5 ohm between the high voltage positive contactor terminal X2 and drive motor generator battery positive terminal.
锟斤拷If greater than the specified range, replace the drive motor positive relay cable.
7. Disconnect the X5 harness connector at the drive motor generator battery control module.
8. Test for less than 5 ohm between the high voltage negative contactor terminal X3 and the ground terminal 5 X5.
锟斤拷If greater than the specified range, replace the drive motor battery positive and negative cable.
9. Test for less than 5 ohm between the high voltage positive contactor terminal X3 and drive motor generator battery control module terminal 1
X5.
锟斤拷If greater than the specified range, replace the drive motor positive and negative cable.
10. Disconnect the X4 harness connector at the drive motor generator battery control module.
11. Connect the EL-48571 high voltage battery pin out box.
12. Install the high voltage manual disconnect lever. Measure and record each of the 20 battery voltages.
13. Each battery voltage reading should be between 10-19 V.
锟斤拷If not within the specified range, replace the drive motor battery assembly.
14. Each battery voltage reading should be within 1.5 V of each other.
锟斤拷If not within the specified range, replace the drive motor battery assembly.
15. If all circuits test normal, replace the drive motor generator battery control module.
Repair Instructions
Perform the Diagnostic Repair Verification (See: Verification Tests) after completing the repair.
* Drive Motor Battery Negative High Voltage Contactor Relay Replacement ()
* Drive Motor Battery Positive High Voltage Contactor Relay Replacement ()
* Drive Motor Battery Positive and Negative Cable Replacement ()
* Drive Motor Generator Battery Replacement and Shipping Preparation ()
* Control Module References (See: Testing and Inspection/Programming and Relearning) for drive motor generator battery control
replacement, setup and programming
