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.

WARNING:

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.

Vehicle in Service Mode, verify no additional DTCs are set in other control modules.
- If additional DTCs are set
  Refer to Diagnostic Trouble Code (DTC) List - Vehicle .
- If no additional DTCs are set
Connect drive motor battery charger cable to household power outlet, but not the battery charger receptacle.
After 25 seconds, verify drive motor battery charger cable LEDs illuminate solid green.
- If drive motor battery charger cable LEDs do not illuminate solid green
1. Connect a known good drive motor battery charger cable to the same household power outlet.
  - If known good drive motor battery charger cable LEDs illuminate solid green
    Have the service provider check for high frequency noise on the dedicated home outlet. If no high frequency noise is found, replace drive motor battery charger cable.
  - If known good drive motor battery charger cable LEDs do not illuminate solid green
    Have the service provider inspect the household power outlet for insufficient voltage, high frequency noise, or open/high resistance.
- If drive motor battery charger cable LEDs do illuminate solid green
Connect a test lamp between the low voltage circuits listed below on drive motor battery charger cable. Verify the test lamp illuminates.
- Proximity status signal circuit terminal D
- Control pilot signal circuit terminal B
  - If the test lamp does not illuminate
    Replace drive motor battery charger cable.
- If the test lamp does illuminate

NOTE:

The following tests are performed at the X98 hybrid/EV battery charger receptacle and not at the harness connector to the X98 hybrid/EV battery charger receptacle.

Vehicle OFF, test for less than 10 Ω between the control pilot signal terminal B at the X98 hybrid/EV battery charger receptacle and ground.
- If 10 Ω or greater
1. Disconnect the X2 harness connector from K114B hybrid/EV powertrain control module 2
2. Test for less than 2 Ω in the control pilot 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.
- If less than 10 Ω
Vehicle in Service Mode, test for 4.2-4.8 V between the proximity status signal terminal D at the X98 hybrid/EV battery charger receptacle and ground.
- If not within the specified range
1. Vehicle OFF, test for infinite resistance between the proximity status signal circuit and ground.
  - If less than infinite resistance
    Repair the short to ground on the circuit.
  - If infinite resistance
2. Disconnect the X2 harness connector from K114B hybrid/EV powertrain control module 2.
3. Test for less than 2 Ω in the proximity status 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.
- If within the specified range
Test for infinite resistance between the terminals listed below at the X98 hybrid/EV battery charger receptacle:
- 110/220 V A/C Line 1 terminal E and 110/220 V A/C Neutral Line 2 terminal A
- 110/220 V A/C Line 1 terminal E and 110/220 V A/C Ground terminal C
- 110/220 V A/C Line 1 terminal E and Control pilot signal circuit terminal B
- 110/220 V A/C Line 1 terminal E and Proximity status signal circuit terminal D
- 110/220 V A/C Neutral Line 2 terminal A and 110/220 V A/C Ground terminal C
- 110/220 V A/C Neutral Line 2 terminal A and Control pilot signal circuit terminal B
- 110/220 V A/C Neutral Line 2 terminal A and Proximity status signal circuit terminal D
- 110/220 V A/C Ground terminal C and Control pilot signal circuit terminal B
- Control pilot signal circuit terminal B and Proximity status signal circuit terminal D
  - If less than infinite resistance
    Repair the short between the circuits.
- If within the specified range
Test for 2.56-2.84k Ω between the 110/220 V A/C Ground terminal C and Proximity status signal circuit terminal D at the X98 hybrid/EV battery charger receptacle.
- If less than specified range
1. Disconnect the harness connector from the X98 hybrid/EV battery charger receptacle.
2. Test for infinite resistance between the 110/220 V A/C Ground terminal C and Proximity status signal circuit terminal D of the harness connector.
  - If less than infinite resistance
    Repair the short between the circuits.
  - If infinite resistance
    Replace the X98 hybrid/EV battery charger receptacle.
- If within the specified range
Replace the T18 Battery Charger.