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.

Preliminary Procedures:

1. Disable the high voltage at the drive motor generator battery. Refer to High Voltage Disabling .
2. Remove the upper, front, and right side covers. Refer to Drive Motor Battery Case Upper Cover, Front Cover, and Right Side Cover Replacement .

1

Drive Motor Battery Cable Terminal Nut (Qty: 2)

Notice: Refer to Fastener Notice in the Preface section.

Tighten
5 N·m (44 lb in)

2

Drive Motor Battery Positive Relay Cable Assembly

Caution: 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® Listed, or equivalent, insulation tape rated at a minimum of 600 volts. Damage caused to unprotected terminal ends will result in cable replacement.

Tip
Remove the positive relay from the current sensor to ease removal of the relay.

Special Tools

EL-48569 Terminal Covers

3

Drive Motor Battery Positive and Negative w/Wiring Harness Cable Assembly

Caution: 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® Listed, or equivalent, insulation tape rated at a minimum of 600 volts. Damage caused to unprotected terminal ends will result in cable replacement.

Special Tools

EL-48569 Terminal Covers

4

Wiring Harness Connector

5

Drive Motor Battery Positive High Voltage Contactor Relay Nut (Qty: 2)

Tighten
3 N·m (27 lb in)

6

Drive Motor Battery Negative High Voltage Contactor Relay Assembly

Procedure:

After the relay assembly has been replaced and the re-assembly of the drive motor generator battery, enable the HV system. Refer to High Voltage Enabling .