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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. Vehicle ON.
  3. Verify DTC P0D3E or P0D3F does not set.
    • If none of the DTCs set 

      Direct vehicle owner to verify proper connection of drive motor battery charger cable to their electrical supply and attempt charge again. If the vehicle will not charge, they will need electrical supply serviced.

    • If any of the DTCs set 
  4. 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.

    • If drive motor battery charger cable LEDs are not flickering 
  5. Vehicle OFF, disconnect the drive motor battery charger cable from the vehicle, disable the high voltage at the T18 Battery Charger. Refer to High Voltage Disabling .
  6. Disconnect the X3 harness connector at the T18 Battery Charger.
  7. Test for a short circuit on the AC circuits by testing for infinite resistance between the pairs listed below:
    • T18 Battery Charger AC circuit terminals A X3 and B X3
    • T18 Battery Charger AC circuit terminals A X3 and C X3
    • T18 Battery Charger AC circuit terminals C X3 and B X3
    • T18 Battery Charger AC circuit terminal A X3 and ground
    • T18 Battery Charger AC circuit terminal C X3 and ground
    • If less than infinite resistance 
    1. Disconnect harness connector at the X98 Hybrid/EV Battery Charger Receptacle.
    2. Test for a short circuit on the AC circuits by testing for infinite resistance between the appropriate pair listed below:
      • T18 Battery Charger AC circuit terminals A X3 and B X3
      • T18 Battery Charger AC circuit terminals A X3 and C X3
      • T18 Battery Charger AC circuit terminals C X3 and B X3
      • T18 Battery Charger AC circuit terminal A X3 and ground
      • T18 Battery Charger AC circuit terminal C X3 and ground
      • If less than infinite resistance, repair the short to ground on the circuit.
      • If infinite resistance, replace the X98 Hybrid/EV Battery Charger Receptacle.
    • If infinite resistance 
    8. Fig 1: X98 Hybrid/EV Battery Charger Receptacle And Terminals
    GM2874492Courtesy of GENERAL MOTORS COMPANY
    NOTE:

    The following tests are performed at the external 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 2 Ω in the AC circuits end to end by measuring between the pairs listed below:
    • T18 Battery Charger circuit terminal A X3 and X98 Hybrid/EV Battery Charger Receptacle terminal E
    • T18 Battery Charger circuit terminal C X3 and X98 Hybrid/EV Battery Charger Receptacle terminal A
    • If 2 Ω or greater 
    1. Disconnect the harness connector at the X98 Hybrid/EV Battery Charger Receptacle.
      2. NOTE:

      This test is performed at the vehicle side of the harness connectors.

    2. Test for less than 2 Ω in the AC circuit end to end by measuring between the appropriate pair listed below:
      • T18 Battery Charger circuit terminal A X3 and X98 Hybrid/EV Battery Charger Receptacle harness connector circuit terminal E
      • T18 Battery Charger circuit terminal C X3 and X98 Hybrid/EV Battery Charger Receptacle harness connector circuit terminal A
      • If 2 Ω or greater, repair the open/high resistance in the circuit.
      • If less than 2 Ω, replace the X98 Hybrid/EV Battery Charger Receptacle.
    • If less than 2 Ω 
  9. Replace the T18 Battery Charger.
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