Rechargeable Energy Storage System Smoke Test

Special Tools

• EL-52015  Volt Battery Smoke Test Leak Adapters
• GE 41413-A  Evaporative Emissions System Tester (EEST)

Equivalent regional tools: Special Tools

1. Remove the drive motor battery. Drive Motor Battery Replacement and Shipping Preparation , or Drive Motor Battery Replacement and Shipping Preparation (Forklift Method) , or Drive Motor Battery Replacement and Shipping Preparation (Engine Hoist/Pallet Jack Method)

2. Courtesy of GENERAL MOTORS COMPANY

   Install the EL-52015  Drive Motor Battery smoke test leak adapters to the following Drive Motor Battery Connectors:

   • X1
   • X2
   • X3

3. Courtesy of GENERAL MOTORS COMPANY

   Cover all gore patches (1, 2, 3 and 4) with tape.

   NOTE:

   Duct tape is not recommended because of damage to the Gore patches when removing.

NOTE:

It is not recommended to use the tester in an outside repair bay area because wind and sunlight may affect temperature and your ability to see the smoke.

4. Turn OFF any fans that may cause air movement around or near the Drive Motor Battery.

5. Courtesy of GENERAL MOTORS COMPANY

   Install the GE 41413-A  Evaporative Emissions System Tester (EEST) to connector (X4).

NOTE:

Completely unwind the smoke hose from the bracket for optimal tester performance.

6. Turn the nitrogen/smoke valve on the control panel to smoke.
NOTE:

The remote switch operates in a push ON, push OFF fashion.

7. Press and release the remote switch to activate the tester and inject smoke into the Drive Motor Battery.

8. Courtesy of GENERAL MOTORS COMPANY

   Soak/Fill the RESS with smoke for FIVE MINUTES until smoke is observed from the manual service disconnect connector (1).

9. Install the manual service disconnect lever. High Voltage Battery High Voltage Manual Disconnect Lever Replacement
10. Introduce smoke into the Drive Motor Battery for up to THREE MINUTES. Using a high-intensity white light, look for any visible smoke emitting anywhere from the Drive Motor Battery.
11. Press and release the remote switch to deactivate the tester.
12. Repair any visible leaks by retightening the fasteners or by resealing any areas.
13. Retest the Drive Motor Battery, to ensure repair has been completed.
14. Remove the masking tape from the gore patches (1, 2, 3 and 4).
15. Remove the manual service disconnect lever. High Voltage Battery High Voltage Manual Disconnect Lever Replacement
16. Open the nitrogen tank valve and turn the nitrogen/smoke valve on the control panel to Nitrogen.
17. Press and release the remote switch to activate the tester and inject nitrogen into the Drive Motor Battery for FIVE MINUTES, verify no smoke is coming from the vent.
18. Remove all old vents from the Drive Motor Battery.
19. Install NEW Gore patches (P/N 20791600), replacing the old vents.
20. Disconnect the tester and remove the adapters from the Drive Motor Battery.
21. Install the drive motor battery. Drive Motor Battery Replacement and Shipping Preparation , or Drive Motor Battery Replacement and Shipping Preparation (Forklift Method) , or Drive Motor Battery Replacement and Shipping Preparation (Engine Hoist/Pallet Jack Method)