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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.

NOTE:

For European Region, a face shield is required in place of safety glasses.

WARNING:

High voltage circuits should only be tested using a digital multimeter (DMM) and test leads with at least a CAT III rating, such as the J 39200-A Digital Multimeter. Failure to follow the procedures may result in serious injury or death.

NOTE:

For European Region, a special voltage tester such as the EL-52229 may be required. A multimeter that can measure current is prohibited.

WARNING:

This vehicle is equipped with a high voltage battery that is completely isolated from the chassis ground. Never utilize AC powered test equipment to probe the high voltage system. Serious injury, death and component damage could occur if the high voltage system is grounded through the electric utility.

Failure to follow the procedure exactly as written may result in serious injury or death.

WARNING:

Before working internally on the high voltage battery, be sure to wear Personal Protection Equipment (PPE) in accordance with National Fire Protection Association (NFPA) 70E, PPE Category 2, Minimum Arc Rating 12 cal/cm 2:

  • Safety helmet, face shield and sock hood/balaclava
  • Safety rated long sleeve shirt and pants or safety rated coveralls.
  • Hearing protection
  • 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 these precautions could result in serious personal injury or death.
  1. Vehicle Power Mode State: OFF  and all vehicle systems OFF. It may take up to 10 minutes for all vehicle systems to power down.
  2. Disable high voltage. High Voltage Disabling
    3. NOTE:
    • Refer to Diagnostic Aids to ensure poor connectivity is not causing DTCs to set.
    • Visually inspect the X98 Battery Charger Coupler to ensure no physical damage. If is damage found, replace the X98 Battery Charger Coupler before further diagnostics.
  3. Verify DTC P2E85 and P0D3F are not set  .
    • If DTCs are set 

      An in-line connector between the X98 Battery Charger Coupler and the T18B Battery Charger 2could have a poor connection. Visually inspect all in-line connections between the X98 Battery Charger Coupler and the T18B Battery Charger 2

    • If Go to next step: DTC P2E85 and P0D3F are not set 
  4. Disconnect the X1 harness connector at the T18B Battery Charger 2
  5. Test for less than 2 Ω between the following circuits end to end:
    • X98 Battery Charger Coupler terminal 5 and the X1 connector terminal 2 T18B Battery Charger 2
    • X98 Battery Charger Coupler terminal 2 and the X1 connector terminal 1 T18B Battery Charger 2
    • GM4568248Courtesy of GENERAL MOTORS COMPANY
    • If 2 ohms or Greater 
    1. Disconnect the inline connector between the T18B Battery Charger 2 and the X98 Battery Charger Coupler. Test for less than 2 Ω between:
      • The X1 connector terminal 1 on the inline connector and terminal 5 on the X98 Battery Charger Coupler
      • The X1 connector terminal 2 on the inline connector and terminal 2 on the X98 Battery Charger Coupler
      • If 2 ohms or Greater  on either circuit

        Replace X98 Battery Charger Coupler

      • Go to next step: If less than 2 ohms 
    2. At the inline connector, test between:
      • The X1 connector terminal 1 at the inline connector and the X2 Terminal 2 at the T18B Battery Charger 2
      • The X1 connector terminal 2 at the inline connector and the X2 Terminal 1 at the T18B Battery Charger 2
      • If 2 ohms or Greater 

        Replace the HIgh Voltage Battery positive and negative cables.

      • Go to next step: If less than 2 ohms 
    3. Replace the component: T18 Battery Charger
    • Go to next step: If less than 2 ohms 
  6. Replace the component: T18 Battery Charger
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