High Voltage Shutdown Procedure for Pure Electric Vehicles

The high voltage shutdown procedure for pure electric vehicles (EVs) is a critical safety step to deactivate the high-voltage system before maintenance or emergency situations. Here’s how to do it safely:

1. Turn off the vehicle: Ensure the EV is in 'Park' mode and the ignition is switched off.
2. Disconnect the 12V battery: This prevents accidental activation of the high-voltage system.
3. Locate the high-voltage service disconnect: Found under the bonnet or boot in most EVs (e.g., Tesla Model 3, Nissan Leaf).
4. Remove the disconnect: Follow the manufacturer’s instructions—typically involves unplugging a bright orange connector.
5. Wait 10-15 minutes: High-voltage capacitors need time to discharge.

Always refer to the vehicle manual for model-specific steps. Never attempt this without proper training—EV high-voltage systems can exceed 400V, posing severe risks. For emergency responders, manufacturers often provide rescue sheets detailing shutdown points.

From a technician’s perspective: Shutting down an EV’s high-voltage system requires precision. After powering off, isolate the 12V battery to cut auxiliary power. The high-voltage disconnect—often marked in orange—must be removed carefully. Capacitors retain charge, so waiting is non-negotiable. Missteps can lead to arc flashes or system damage. Always use insulated tools and PPE.

The high voltage shutdown process for new energy vehicles consists of 5 steps

1. Turn off the vehicle ignition key
2. Disconnect the negative terminal of the battery
3. Remove the maintenance switch. After opening, dust and moisture protection measures should be implemented.
4. Wait for 5 minutes to allow for discharge time.
5. Disconnect the high voltage connector of the power battery and perform voltage verification. When the voltage is within the safe range, the high voltage shutdown is complete.

Hope this helps. Thank you for your adoption.