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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.

    Fig 1: Harness Connector Terminals
    GM3702546Courtesy of GENERAL MOTORS COMPANY
    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.

  1. Vehicle OFF and all vehicle systems OFF. It may take up to 2 minutes for all vehicle systems to power down. Test for 1.5-1.7k Ω between the control pilot signal terminal 4 at the X98 Hybrid/EV Battery Charger Receptacle and ground.
    • If greater than 1.7k Ω 
    1. Disconnect the X2 harness connector from K114B Hybrid/EV Powertrain Control Module 2
    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 1.5k Ω 
    1. Disconnect the X2 harness connector from K114B Hybrid/EV Powertrain Control Module 2.
    2. Test for infinite resistance between the control pilot signal circuit and ground.
      • If infinite resistance, replace the K114B Hybrid/EV Powertrain Control Module 2.
      • If less than infinite resistance
    3. Vehicle OFF, remove the High Voltage Disconnect Circuit Connector Cover. Refer to High Voltage Disconnect Circuit Connector Cover Replacement . Disconnect the X7 harness connector at the T24 Battery Charger - DC.
    4. 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 T24 Battery Charger - DC.
    • If within the specified range 
    2. Fig 2: Harness Connector Terminals
    GM3702546Courtesy of GENERAL MOTORS COMPANY
  2. 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 
    3. Fig 3: Harness Connector Terminals
    GM3702546Courtesy of GENERAL MOTORS COMPANY
  3. Vehicle in Service Mode.
  4. 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 
    1. Vehicle OFF, disconnect the X2 harness connector from K114B Hybrid/EV Powertrain Control Module 2. Vehicle in Service Mode.
    2. 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 greater than 1 V
    3. Vehicle OFF, remove the High Voltage Disconnect Circuit Connector Cover. Refer to High Voltage Disconnect Circuit Connector Cover Replacement . Disconnect the X7 harness connector at the T24 Battery Charger - DC. Vehicle in Service Mode.
    4. 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 T24 Battery Charger - DC.
    • If less than 1 V 
    5. Fig 4: Harness Connector Terminals
    GM3702546Courtesy of GENERAL MOTORS COMPANY
  5. 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 
    1. Vehicle OFF.
    2. 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
    3. Disconnect the X2 harness connector from K114B Hybrid/EV Powertrain Control Module 2.
    4. 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 
    1. Vehicle OFF, disconnect the X2 harness connector from K114B Hybrid/EV Powertrain Control Module 2. Vehicle in Service Mode.
    2. 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 
  6. Vehicle OFF, disconnect the X2 harness connector from T24 Battery Charger DC.
    7. Fig 5: Harness Connector Terminals
    GM3702546Courtesy of GENERAL MOTORS COMPANY
    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.

  7. Test for infinite resistance between the terminals listed below at the X98 Hybrid/EV Battery Charger Receptacle;
    • 480 V DC Positive terminal DC+ and 480 V DC Negative terminal DC-
    • 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 
    8. Fig 6: Harness Connector Terminals
    GM3702546Courtesy of GENERAL MOTORS COMPANY
    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.

  8. Test for less than 10 Ω between the terminals listed below;
    • 480 V DC Positive terminal DC+ at the X98 Hybrid/EV Battery Charger Receptacle and terminal A X2
    • 480 V DC Negative terminal DC- at the X98 Hybrid/EV Battery Charger Receptacle and terminal B X2
    • If 10 Ω or greater 

      Repair the open/high resistance in the circuit.

    • If less than 10 Ω 
  9. Disconnect the X1 harness connector from the X98 Hybrid/EV Battery Charger Receptacle.
    10. Fig 7: Harness Connector Terminals
    GM3702546Courtesy of GENERAL MOTORS COMPANY
  10. 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 
  11. Replace the T24 Battery Charger - DC.
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