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Circuit/System Testing

WARNING:

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.

  1. Vehicle OFF, disable the high voltage at the T18 Battery Charger. Refer to High Voltage Disabling . Reconnect the X2 harness connector at the T18 Battery Charger.
  2. GM4177681Courtesy of GENERAL MOTORS COMPANY
    NOTE:

    The following tests are performed at the X98 Hybrid/EV Battery Charger Receptacle face and not at the harness connector to the X98 Hybrid/EV Battery Charger Receptacle.

    Test for less than 10 Ω between the low reference circuit terminal 1 and ground.

    • If 10 Ω or greater 
    1. Disconnect the X2 harness connector at the T18 Battery Charger.
    2. Test for less than 2 Ω in the low reference circuit end to end.
      • If 2 Ω or greater
      1. Disconnect the X98 Hybrid/EV Battery Charger Receptacle inline connector.
      2. Test for less than 2 Ω in the low reference circuit end to end, from the receptacle face to the inline connector terminal.
        • If 2 Ω or greater, replace the X98 Hybrid/EV Battery Charger Receptacle.
        • If less than 2 Ω, replace the vehicle harness circuit.
      • If less than 2 Ω
    3. Replace the T18 Battery Charger.
    • Go to next step: If less than 10 Ω 
  3. Connect the 12 V battery. Vehicle in Service Mode.
  4. GM4177681Courtesy of GENERAL MOTORS COMPANY

    Test for 4.2 - 4.8 V between the signal circuit terminal 5 and ground.

    • If less than 4.2 V 
    1. Vehicle OFF, disconnect the harness connector to the X98 Hybrid/EV Battery Charger Receptacle. Vehicle in Service Mode.
      2. NOTE:

      The following tests are performed at the vehicle-side harness connector to the X98 Hybrid/EV Battery Charger Receptacle.

    2. Test for 4.8 V or greater between the signal circuit terminal 5 and ground.
      • If less than 4.8 V
      1. Disconnect the X2 harness connector at the K114B Hybrid/EV Powertrain Control Module 2.
      2. Test for infinite resistance between the signal circuit terminal 5 and ground.
        • If less than infinite resistance, repair the short to ground in the circuit.
        • Go to next step: If infinite resistance
      3. Test for less than 2 Ω in the signal circuit end to end.
        • If 2 Ω or greater, repair the open/high resistance in the circuit.
        • If less than 2 Ω, replace the K114B Hybrid/EV Powertrain Control Module 2.
      • Go to next step: If 4.8 V or greater
    3. Replace the X98 Hybrid/EV Battery Charger Receptacle.
    • Go to next step: If greater than 4.8 V 
    1. Vehicle OFF, disconnect the X2 harness connector at the T18 Battery Charger. Disconnect the harness connector to the X98 Hybrid/EV Battery Charger Receptacle. Vehicle in Service Mode.
      2. NOTE:

      The following tests are performed at the vehicle-side harness connector to the X98 Hybrid/EV Battery Charger Receptacle.

    2. Test for 4.8 - 5.2 V between the signal circuit terminal 5 and ground.
      • If greater than 5.2 V
      1. Disconnect the X2 harness connector at the K114B Hybrid/EV Powertrain Control Module 2.
      2. Test for less than 1 V between the signal circuit terminal 5 and ground.
        • If 1 V or greater, repair the short to voltage in the circuit.
        • If less than 1 V, replace the K114B Hybrid/EV Powertrain Control Module 2.
      • Go to next step: If within 4.8 - 5.2 V
      3. NOTE:

      The following tests are performed at the X98 Hybrid/EV Battery Charger Receptacle face.

    3. Test for 2.565 - 2.835K Ω between the signal circuit terminal 5 and the low reference circuit terminal 1.
      • If not within the specified range, replace the X98 Hybrid/EV Battery Charger Receptacle.
      • If within the specified range, replace the K114B Hybrid/EV Powertrain Control Module 2.
    • Go to next step: If within 4.2 - 4.8 V 
  5. Vehicle OFF and all vehicle systems OFF. It may take up to 2 minutes for all vehicle systems to power down. Disconnect the X2 harness connector from T18 Battery Charger and the X2 harness connector from the K114B Hybrid/EV Powertrain Control Module 2.
  6. Test for infinite resistance between the signal circuit terminal 5 of the X98 Hybrid/EV Battery Charger Receptacle face and the terminals listed below:
    • Terminal 4
    • Terminal 2
    • Terminal 3
    • If less than infinite resistance 
    1. Vehicle OFF, disconnect the harness connector to the X98 Hybrid/EV Battery Charger Receptacle.
    2. Retest for infinite resistance between signal circuit terminal 5 of the X98 Hybrid/EV Battery Charger Receptacle face and the terminals listed below:
      • Terminal 4
      • Terminal 2
      • Terminal 3
      • If less than infinite resistance replace the X98 Hybrid/EV Battery Charger Receptacle.
      • If infinite resistance, repair the short between the circuits in the vehicle wiring harness.
    • Go to next step: If infinite resistance 
  7. Replace the K114B Hybrid/EV Powertrain Control Module 2.
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