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 at the T18 Battery Charger. High Voltage Disabling .
- Disconnect the X2 harness connector at the K16A Battery Energy Control Module 1.
- NOTE:
The following tests are Performed at the X98 Hybrid/EV Battery Charger Coupler and not at the harness connector to the X98 Hybrid/EV Battery Charger Receptacle.
Test for infinite resistance between the control pilot signal circuit terminal 2 of the X98 Hybrid/EV Battery Coupler Receptacle and the terminals listed below:
- Terminal 1
- Terminal 3
- Terminal 4
- Terminal 5
- If less than infinite resistance
- Disconnect the X2 harness connector at the X98 Hybrid/EV Battery Charger Coupler.
- Test for infinite resistance between the harness connector control pilot signal circuit terminal 2 and the terminals listed below:
NOTE:This test is Performed on the vehicle side of the harness connector.
- Terminal 1
- Terminal 3
- If less than infinite resistance, repair the short between the circuits.
- If infinite resistance, replace the X98 Hybrid/EV Battery Charger Coupler.
- Go to next step: If infinite resistance
- Test for less than 2 Ω in the control pilot signal circuit end to end.
- If 2 Ω or Greater
- Disconnect the X2 harness connector at the X98 Hybrid/EV Battery Charger Coupler.
- Test for less than 2 Ω in the control pilot signal circuit end to end.
- If 2 Ω or Greater, replace the X98 Hybrid/EV Battery Charger Coupler.
NOTE:This test is Performed at the X98 Hybrid/EV Battery Charger Coupler.
- Go to next step: If less than 2 Ω
- Replace the K16A Battery Energy Control Module 1.