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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. Verify DTC P1EC5, P0D48, P0D59, P0CF4, P0CF5, P0CF6, or any other battery charger DTC is not set.
    • If none of the DTCs are set 
  2. Verify DTC P0D26 is not set.
    • If the DTC is set 
      NOTE:

      Disabling the high voltage as directed is a critical part of this procedure. It will cycle 12 V battery power and wiring harness connections at the T18 Battery Charger.

    1. Vehicle OFF. Disable the high voltage system for servicing the T18 Battery Charger and X98 Hybrid/EV Battery Charger Receptacle. Refer to High Voltage Disabling .
    2. Disconnect the vehicle wiring harness connector at the X98 Hybrid/EV Battery Charger Receptacle.
    3. Verify that the X98 Hybrid/EV Battery Charger Receptacle harness connector and the mating vehicle wiring harness connector terminals are free from moisture, corrosion, and damage.
      • If any terminals show signs of moisture damage or intrusion, such as corrosion or moisture, replace the X98 Hybrid/EV Battery Charger Receptacle and repair the vehicle wiring harness as necessary.
      • If any terminals or connectors show signs of physical damage, without signs of moisture intrusion, repair or replace as necessary.
      • If no damage, moisture, or corrosion is found
    4. Connect the vehicle wiring harness connector at the X98 Hybrid/EV Battery Charger Receptacle.
    5. Enable the high voltage system. Refer to High Voltage Enabling .
    6. Verify DTC P0D26 sets.
      • If the DTC does not set, all OK.
      • If the DTC sets
    7. Replace the X98 Hybrid/EV Battery Charger Receptacle.
    8. Verify DTC P0D26 does not set.
      • If the DTC sets, replace the T18 Battery Charger.
      • If the DTC does not set
    9. All OK.
    • If the DTC is not set 
  3. All OK.
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