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 less than 10 Ω between the terminal 3 and ground.
- If 10 Ω or greater
- Test for less than 2 Ω the ground circuit end to end.
- If 2 Ω or greater, replace the high voltage cables.
- If less than 2 Ω, repair the open/high resistance in the ground connection.
- If less than 10 Ω
- Test for 2.565-2.835K Ω between the signal circuit terminal 5 and the ground circuit terminal 3.
- 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
- Connect the 12 V battery. Vehicle in Service Mode.
- Test for 4.2-4.8 V between the proximity signal circuit terminal 5 and ground.
- If less than 4.2 V
- Vehicle OFF, disconnect the X2 harness connector at the K114B Hybrid/EV Powertrain Control Module 2.
- Test for infinite resistance between the signal circuit terminal 5 and ground.
- If less than infinite resistance, repair the short to ground in the circuit.
- If infinite resistance
- Test for less than 2 Ω the 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 greater than 4.8 V
- Vehicle OFF, disconnect the X2 harness connector at the K114B Hybrid/EV Powertrain Control Module 2. Vehicle in Service Mode.
- Test for less than 1.0 V between the signal circuit terminal 5 and ground.
- If 1.0 V or greater, repair the short to voltage in the circuit.
- If less than 1.0 V, replace the K114B Hybrid/EV Powertrain Control Module 2.
- If between 4.2-4.8 V
- Test for infinite resistance between control pilot signal circuit terminal 5 of the X98 Hybrid/EV Battery Charger Receptacle and the terminals listed below;
- Terminal 1
- Terminal 2
- Terminal 4
- If less than infinite resistance
Repair the short between the circuits.
- If less than 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.