High Voltage Service Disconnect

This procedure safely disconnects the high voltage system on the 2022 Rivian EDV 500, isolating the battery pack from all vehicle electrical systems to enable safe maintenance work on high voltage components.

Warnings

Tools required

Parts

• High voltage service disconnect cover seal × 1 — Use OEM specification
• Service disconnect lock pin × 1 — Use OEM specification

Preparation

1. Verify vehicle is parked on level ground with parking brake engaged
2. Ensure all doors, windows, and charge port are closed
3. Place high voltage warning signs around vehicle work area
4. Position Class C fire extinguisher within immediate reach
5. Verify insulated gloves have no cuts, tears, or damage and are within certification date
6. Test multimeter on known voltage source to verify operation
7. Document vehicle state and any warning lights on instrument cluster
8. Take photographs of all connector orientations before disconnection
9. Ensure no personnel are inside vehicle cabin during disconnect procedure

Procedure

1. 1

   Power down vehicle systems
   Ensure vehicle is in Park mode. Press and hold the power button until all displays shut down completely. Verify instrument cluster is completely dark. Wait 60 seconds for all vehicle control modules to enter sleep mode. Verify no sounds from cooling fans or pumps.
2. 2

   Disconnect 12V battery
   Open hood and locate 12V auxiliary battery in front compartment. Using 10mm socket, disconnect negative terminal first, then positive terminal. Isolate terminals so they cannot contact battery posts. This removes power from vehicle control systems but does NOT disconnect high voltage.
3. 3

   Access high voltage service disconnect
   Locate the high voltage service disconnect panel on the underside of the vehicle, centered between the front seats. The disconnect is housed in an orange-colored enclosure. Remove the access panel cover by removing four T30 Torx screws. Lower the panel carefully and set aside.
   ⚠️Orange components and cables indicate HIGH VOLTAGE. Do not proceed without proper insulated gloves.
4. 4

   Don high voltage protective equipment
   Put on Class 0 insulated gloves rated for minimum 1000V. Inspect gloves one final time for any damage. Ensure gloves are dry and clean. Keep insulated gloves on for all subsequent steps involving contact with orange components.
5. 5

   Remove service disconnect cover
   With insulated gloves on, locate the orange high voltage service disconnect housing. Remove the safety cover by pressing the release tab and rotating counterclockwise approximately 45 degrees. Lift cover straight up to reveal the disconnect plug assembly. Inspect area for any signs of arcing, melting, or corrosion.
6. 6

   Unlock disconnect mechanism
   Locate the mechanical safety lock on the disconnect plug. This is a spring-loaded pin mechanism on the side of the disconnect assembly. Press the release button and rotate the safety lock counterclockwise 90 degrees until it stops. The lock should remain in the open position.
7. 7

   Extract service disconnect plug
   Grasp the orange disconnect plug handle firmly with both hands. Pull straight down with steady force until the plug releases from the housing. The plug will travel approximately 6 inches. Do NOT twist or rock the plug during removal. Set the plug in a safe location away from the vehicle where it cannot be accidentally reinstalled.
   ⚠️High voltage is now interrupted but capacitors remain charged. Do NOT touch any terminals or orange cables.
8. 8

   Install lockout device
   Insert the lockout/tagout device into the service disconnect receptacle to prevent accidental reconnection. Attach a tag indicating your name, date, time, and reason for disconnect. This prevents others from reconnecting high voltage while you are working.
9. 9

   Wait for capacitor discharge
   Wait minimum 15 minutes for high voltage capacitors in inverters and charging system to fully discharge. Set a timer and do not proceed until full time has elapsed. During this time, maintain work area security and ensure no one attempts to reconnect the system.
10. 10

    Verify voltage isolation
    After 15 minute wait period, set multimeter to DC voltage mode with range of at least 1000V. Still wearing insulated gloves, carefully measure voltage between the positive and negative terminals in the disconnect receptacle. Verify reading is 0V DC (less than 5V residual). Also measure from each terminal to vehicle chassis ground. All readings must be 0V.
    ⚠️If ANY voltage above 5V DC is detected, do not proceed. Wait an additional 15 minutes and retest. If voltage persists, system has a fault requiring specialist diagnosis.
11. 11

    Install terminal protective covers
    If provided with the vehicle, install insulating protective covers over the exposed terminals in the disconnect receptacle. This prevents accidental contact or short circuits. If covers are not available, wrap terminals individually with electrical insulation tape rated for high voltage.
12. 12

    Document disconnect status
    Take photographs showing the disconnect plug removed and lockout device installed. Record the date, time, and multimeter voltage readings in service documentation. Place additional warning tags on the driver's door and charge port indicating high voltage system is disconnected.

Reassembly

1. Before reconnecting, visually inspect all high voltage components and orange cables for any damage caused during service work
2. Remove all tools, parts, and materials from high voltage component areas
3. Remove insulating covers or tape from disconnect receptacle terminals
4. Inspect disconnect plug for any damage, corrosion, or debris on contact surfaces
5. Align disconnect plug with receptacle and push firmly upward until fully seated with an audible click
6. Rotate safety lock clockwise 90 degrees to locked position
7. Install service disconnect cover by aligning tabs and rotating clockwise 45 degrees until secure
8. Verify cover seal is properly positioned and shows no damage
9. Reinstall access panel and secure with four T30 Torx screws
10. Remove lockout/tagout device and all warning tags from vehicle
11. Reconnect 12V battery: positive terminal first, then negative terminal, tighten with 10mm socket
12. Remove all high voltage warning signs from work area

Verification

• With vehicle still off, verify no high voltage warning lights illuminate when 12V battery is reconnected (indicates short circuit)
• Power on vehicle and verify READY status on instrument cluster
• Check for any high voltage system fault codes using diagnostic scanner
• Verify cooling system pump operates normally (listen for pump operation)
• Verify instrument cluster shows expected battery state of charge
• Perform a low-speed test drive in safe area to confirm both motors operate normally
• Verify regenerative braking functions properly during test drive
• Check that battery thermal management system activates if needed
• Confirm no unusual sounds, smells, or warning messages during initial operation
• Document successful reconnection with date, time, and verification results in service records

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