Circuit/System Testing
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.
- Vehicle OFF, disable the high voltage. Refer to High Voltage Disabling
- Test for 100k Ω-4M Ω between the control pilot signal terminal 4 at the X98 Hybrid/EV Battery Charger Receptacle and ground.
- If 4M Ω or greater
- Disconnect the X2 harness connector from K114B Hybrid/EV Powertrain Control Module 2.
- Test for 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 100k Ω
- Disconnect the X2 harness connector from K114B Hybrid/EV Powertrain Control Module 2.
- Test for infinite resistance between the control pilot signal circuit and ground.
- If less than infinite resistance, repair the short to ground in the circuit.
- If infinite resistance, replace the K114B Hybrid/EV Powertrain Control Module 2.
- If within the specified range
- Connect the 12 V battery. Vehicle in Service Mode.
- Test for less than 1 V between the control pilot signal terminal 4 at the X98 Hybrid/EV Battery Charger Receptacle and ground.
- If 1 V or greater
- Vehicle OFF, disconnect the X2 harness connector from K114B Hybrid/EV Powertrain Control Module 2. Vehicle in Service Mode.
- Test for less than 1 V between the control pilot signal circuit and ground.
- If greater than 1 V, repair the short to voltage in the circuit.
- If less than 1 V, replace the K114B Hybrid/EV Powertrain Control Module 2.
- If less than 1 V
- Test for infinite resistance between control pilot signal circuit terminal 4 of the X98 Hybrid/EV Battery Charger Receptacle and the terminals listed below;
- Terminal 1
- Terminal 2
- Terminal 3
- Terminal 5
- If less than infinite resistance
Repair the short between the circuits.
- If infinite resistance
- Replace the K114B Hybrid/EV Powertrain Control Module 2.
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.
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.