High Voltage Safety
High Voltage Safety
Diagnostic Instructions
* Perform the Diagnostic System Check - Vehicle Diagnostic System Check - Vehicle prior to using this diagnostic procedure.
* Review Strategy Based Diagnosis Strategy Based Diagnosis for an overview of the diagnostic approach.
* Diagnostic Procedure Instructions Diagnostic Procedure Instructions provides an overview of each diagnostic category.
Circuit/System Description
The High Voltage Safety procedure will perform the following tasks:
* Identify precautions when performing service or inspections.
* Identify labels for components, wire harness, and connectors.
* Identify high voltage insulation glove inspection procedure.
Reference Information
Schematic Reference
Hybrid Energy Storage Schematics Hybrid Energy Storage Schematics
Connector End View Reference
Component Connector End Views Hybrid/EV Battery Pack X1
Description and Operation
Drive Motor Battery System Description Drive Motor Battery System Description
Electrical Information Reference
* Circuit Testing Circuit Testing
* Connector Repairs Connector Repairs
* Testing for Intermittent Conditions and Poor Connections Testing for Intermittent Conditions and Poor Connections
* Wiring Repairs Wiring Repairs
DTC Type Reference
Powertrain Diagnostic Trouble Code (DTC) Type Definitions Powertrain Diagnostic Trouble Code (DTC) Type Definitions
Scan Tool Reference
Control Module References Programming and Relearning for scan tool information
Circuit/System Testing
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 includes the following steps:
* 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.
Before working on any high voltage system, be sure to wear the following Personal Protection Equipment:
* Safety glasses with appropriate side shields when within 15 meters (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 with leather protectors at all times when working with the high voltage battery assembly, whether the system is energized or not.
Failure to follow the procedures may result in serious injury or death.
Danger: High voltage circuits should only be tested using a digital multimeter (DMM) and test leads with at least a CAT III rating, such as the J 39200-A Digital Multimeter. Failure to follow the procedures may result in serious injury or death.
Danger:
This vehicle is equipped with a high voltage battery that is completely isolated from the chassis ground. Never utilize AC powered test equipment to probe the high voltage system. Serious injury, death and component damage could occur if the high voltage system is grounded through the electric utility.
Failure to follow the procedure exactly as written may result in serious injury or death.
Danger: The Volt Battery Pack will utilize an exchange program. Please consult the most recent revision of bulletin/PI #PIP4841, available in Service Information (SI), for a list of approved Volt Battery Pack service procedures. Components that may be removed and serviced without exchanging the complete battery pack are identified in the bulletin/PI. Please contact the GM Technical Assistance Center if you have any questions.
Precautions when Performing Service or Inspections
* Always verify that the high voltage has been disabled before working on or around high voltage components, wires, cables, or harnesses.
* Remove all metal objects such as rings and watches.
* The EL-48900 - HEV safety kit contains safety cones. Place the safety cones around the vehicle to alert other technicians that you are working on the high voltage system.
* Remove all keyless entry transmitters and the manual service disconnect from the vehicle and secure in a place outside the vehicle.
* Always wear certified and tested high voltage insulation gloves when inspecting or testing any high voltage wires and components.
* Use the "One Hand" rule:
- Work with only one hand whenever possible.
- Keep the other hand behind your back.
* DO NOT carry any metal objects such as a mechanical pencil or a measuring tape that could fall and cause a short circuit.
* After removing any high voltage wires, protect and insulate the terminal ends immediately with the EL-50209 - high voltage terminal cover and UL(R) Listed or equivalent insulation tape rated at a minimum of 600 V.
* Always tighten the high voltage terminal fasteners to the specified torque. Insufficient or excessive torque will cause malfunctions or damage.
* After finishing work on the high voltage systems and before reinstalling the high voltage manual disconnect, inspect for the following:
- Verify high voltage system integrity and that all connectors are installed.
- Verify that all tools or loose components have been removed.
Labels for Components, Wire Harness, and Connectors
The wire harnesses and cables for high voltage circuits are encased in an orange colored covering. In addition, high voltage components such as the Energy Storage System and high voltage cables are affixed with "High Voltage" red danger (1) and orange warning (2) labels.
High Voltage insulation Glove Inspection Procedure
The following procedure visually and functionally inspects the insulation gloves to be used while performing service on high voltage systems. This inspection procedure should be performed prior to any procedure that requires the use of class "0" insulation gloves rated at 1000 V.
1. Remove glove from leather protector.
2. Inflate glove and seal opening. Pinch the opening closed tightly to prevent any air loss.
3. Press glove to increase pressure.
4. Inspect for the following conditions:
* Pin holes
* Air leaks
* Wear, tears, or abrasions
* Damp or wet material
* Certified up-to-date
• If any of the above conditions are met, do not use the gloves.