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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. Clear DTC, connect the drive motor battery charger cable to vehicle and known good household supply voltage.
  2. Verify DTC P0D3E or P0D3F is set.
    • If DTC is not set, vehicle owner will have to attempt charge at home again. If the vehicle will not charge they will need electrical supply serviced.
  3. Verify drive motor battery charger cable LEDs are not flickering.
    • If drive motor battery charger cable LEDs are flickering, replace drive motor battery charger cable.
  4. Test for infinite resistance between the 110/220 V AC circuit terminals listed below and ground:
    • T18 battery charger terminal A X3
    • T18 battery charger terminal CX3
    • If less than the specified range, test the 110/220 V AC circuit for a short to ground.
  5. Test for less than 10 Ω between the 110/220 V AC circuit terminals listed below:
    • T18 battery charger terminal A X3 and X98 hybrid battery charger receptacle E
    • T18 battery charger terminal C X3 and X98 hybrid battery charger receptacle A
    • If greater than the specified range, test the 110/220 V AC circuit for an open/high resistance.
  6. Test for infinite resistance between the 110/220 V AC circuit at the T18 battery charger terminal A X3 and C X3.
    • If less than the specified range, test the 110/220 V AC circuits for a short between the circuits.
  7. If all circuits tests normal, replace the T18 battery charger.
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