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.
- Test for B+ between the low voltage circuits listed below on drive motor battery charger cable.
- Control pilot signal circuit terminal 4
- Proximity status signal circuit terminal 5
- If not B+
Replace drive motor battery charger cable.
- If B+
- Vehicle OFF and all vehicle systems OFF. It may take up to 2 minutes for all vehicle systems to power down. 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 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
- Test for less than 10 Ω between the 110/220 V A/C Ground terminal 3 at the X98 Hybrid/EV Battery Charger Receptacle and ground.
- If 10 Ω or greater
Repair the open/high resistance in the circuit.
- If less than 10 Ω
- If 10 Ω or greater
- 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 4.2-4.8 V between the proximity status signal terminal 5 at the X98 Hybrid/EV Battery Charger Receptacle and ground.
- If less than 4.2 V
- 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
- Disconnect the X2 harness connector from K114B Hybrid/EV Powertrain Control Module 2.
- 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 4.8 V or greater
- Vehicle OFF, disconnect the X2 harness connector from K114B Hybrid/EV Powertrain Control Module 2. Vehicle in Service Mode.
- Test for 0 V between the proximity status signal circuit and ground.
- If greater than 0 V, repair the short to voltage in the circuit.
- If 0 V, replace the K114B Hybrid/EV Powertrain Control Module 2.
- If within the specified range
- Vehicle OFF, disconnect the X3 harness connector from T18 Battery Charger.
- 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 1 and 110/220 V A/C Neutral Line 2 terminal 2
- 110/220 V A/C Line 1 terminal 1 and 110/220 V A/C Ground terminal 3
- 110/220 V A/C Line 1 terminal 1 and Control pilot signal circuit terminal 4
- 110/220 V A/C Line 1 terminal 1 and Proximity status signal circuit terminal 5
- 110/220 V A/C Neutral Line 2 terminal 2 and 110/220 V A/C Ground terminal 3
- 110/220 V A/C Neutral Line 2 terminal 2 and Control pilot signal circuit terminal 4
- 110/220 V A/C Neutral Line 2 terminal 2 and Proximity status signal circuit terminal 5
- 110/220 V A/C Ground terminal 3 and Control pilot signal circuit terminal 4
- 110/220 V A/C Ground terminal 3 and Proximity status signal circuit terminal 5
- Control pilot signal circuit terminal 4 and Proximity status signal circuit terminal 5
- If less than infinite resistance
Repair the short between the circuits.
- If infinite resistance
- Test for less than 10 Ω between the terminals listed below;
- 110/220 V A/C Line 1 terminal 1 at the X98 Hybrid/EV Battery Charger Receptacle and terminal 3 X3
- 110/220 V A/C Neutral Line 2 terminal 2 at the X98 Hybrid/EV Battery Charger Receptacle and terminal 2 X3
- If 10 Ω or greater
Repair the open/high resistance in the circuit.
- If less than 10 Ω
- If infinite resistance
- Disconnect the harness connector from the X98 Hybrid/EV Battery Charger Receptacle.
- Test for 2.56-2.84k Ω between the 110/220 V A/C Ground terminal 3 and Proximity status signal circuit terminal 5 at the X98 Hybrid/EV Battery Charger Receptacle.
- If not within the specified range
Replace the X98 Hybrid/EV Battery Charger Receptacle.
- If within the specified range
- If not within the specified range
- Test for infinite resistance between the Proximity status signal circuit terminal 5 of the harness connector and ground.
- If less than infinite resistance
Repair short to ground on the circuit.
- If infinite resistance
- If less than infinite resistance
- Replace the T18 Battery Charger.
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.
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.
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.
NOTE:
This test is performed on the vehicle side of the harness connector.