The main disconnect exists as a break in the ground cable from the main negative battery post of the battery pack to remove the power from the 72V system. This switch will kill power to the cabling in the rear of the vehicle, and in-turn the power to the 12V system on vehicles with the DC drive system. On AC drive equipped vehicles, also remove the fuse from the F5 location to kill power to the 12V system. This is very important to use when performing any kind of service on the vehicle’s electrical system. It is very important to note; however, that this does not remove power from the cabling connecting the batteries to each other. This cabling is always live due to the nature of a battery.
Isolated Ground/Shock
Danger
The vehicle electrical system operates with an isolated ground this keeps the chassis free from grounding and is a safety measure taken due to the presence of a high (72V) voltage system. This also makes the vehicle a more service safety friendly. The chassis not being grounded means that even if a metal object (such as a wrench) is placed from a live positive terminal to the chassis there should be no current. This can never be taken for granted however, there may be some circumstance that this is not true due to a service issue or state of disassembly due to a service operation. If a ground cable attached to a battery post is connected with the frame then the frame will be grounded and any positive voltage that comes in contact with the frame will energize it. Extreme caution should always be taken when working with the 72V system and always treat the connections as if they are very dangerous because most of the time they are. Voltage and amperage leakage from the battery pack to the chassis can be tested with a standard voltage test meter.
System Voltages
There are two main system voltages
operating in the vehicle. The first is
the 72V system which consists of the main drive power from the batteries to the
controller and motor. This system is
basically defined by the heavy gauge cabling found throughout the vehicle. This system carries a large supply of power
at 72V and should be treated with great care when servicing or working
around. Connection tightness and
cleanliness in this system are very critical due to the power load
carried. Loose connections could lead to
damage components, loss of system efficiency and even fire and/or shock
hazard.
The second main system voltage is the 12V system which is derived from the 72V system by means of a converter found attached to the firewall underneath the hood. This system is used to power all the accessories inside and outside the vehicle such as all lighting, dash display and most electrical optional components such as the dome light, heater, fan, and the alike. This system is completely isolated from the 72V system. It should be noted that there is also a 12V system that is powered from the controller for the controller operating systems. This system is not isolated from the 72V system. This non-isolated 12V system includes control systems for the controller feedback such as the speedometer readout (dash display), motor speed sensor, direction selector switch, park brake switch, regenerative brake switch and safety switch for the accelerator pedal. Apart from this small subset of the 12V system, the two 72V and 12V systems operate completely isolated from each other including their grounds.
Fuses
72 Volt Fuses
All 72 volt rated fuses are located
in the rear motor compartment of the vehicle.
In most cases, if these fuses fail
there is another issue with your vehicle.
Problems that cause fuse failure should be diagnosed by a trained
professional.
Front Controls Fuse - This
fuse is for the front controls of the vehicle (Ignition, converter, heater,
etc). It is a 30 amp fuse (NON-30).
Main drive System Fuse (AC Drive)
- The main fuse for the 72 volt A.C. drive system which is rated for 425 amps (
12 Volt Fuses
The 12 volt fuses are located at the front of the vehicle beneath the hood. To access them, unlatch and open the hood and remove the aluminum tunnel cover. The fuse panel is a small black box in the center. Remove the weather cover by pressing both of the side tabs and lifting upward. The fuse circuit, size and panel locations are given in the following table:
Fuse Table
| Fuse Location | Circuits Protected | Fuse |
| F1 | Ignition | 7.5 Amp |
| F2 | Hazard & Turn Lights | 10 Amp |
| F3 | Radio | 10 Amp |
| F4 | Interior Dome Light | 5 Amp |
| F5 | 12 Volt Battery (A.C. Drive Only) | 25 Amp |
| F6 | Lithium BMS | 5 Amp |
| F7 | Fuel Fired Heater | 20 Amp |
| F11 | Headlights | 20 Amp |
| F12 | Horn, Backup Alarm, Backup Light, Backup Camera | 15 Amp |
| F13 | Brake Lights, Wiper Motor, 12-volt Accessory Outlet | 15 Amp |
| F14 | Heater Coil, Heater Fan, Radio Ignition | 10 Amp |
| F15 | 2 Speed Fan, Beacon Light | 10 Amp |
| F17 | Air Conditioner/Heater | 20 Amp |