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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. The over-voltage exposure time limit has been reached. DC Series Fast Charging is prevented until the applicable high voltage component is replaced.
    1. Review the battery energy control module scan tool parameters for Rail Over-Voltage Exposure Time. Refer to Diagnostic Aids.
    2. Determine which high voltage component (s) have exceeded their lifetime exposure time limit. Verify no additional high voltage components are close to their exposure time limit.
  2. Disable high voltage for servicing the applicable high voltage component (s). High Voltage Disabling
  3. Replace the applicable high voltage components.
  4. Enable high voltage.
  5. Vehicle in Service Mode.
  6. Perform all applicable scan tool Rail Over-Voltage Exposure Resets in the Battery Energy Control Module. For each of the high voltage component replaced, be sure to reset both the positive and negative rail exposure time to zero.
  7. Turn the vehicle OFF and wait 10 minutes.
    8. NOTE:

    Vehicle conditions like temperature may not allow for immediate level 3 DC series fast charging.

  8. Level 3 DC series fast charging has been enabled.
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