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Home >> Chevrolet >> 2012 >> Volt >> Repair and Diagnosis >> Hybrid/Electric Powertrain >> Battery Management Systems >> Hybrid/EV Energy Storage System >> Diagnostic Information and Procedures >> DTC P0AF8 >> Circuit/System Testing

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.

WARNING:

The Volt Battery Pack will utilize an exchange program. Please consult the most recent revision of bulletin/PI #PIP4841, available in Service Information (SI), for a list of approved Volt Battery Pack service procedures. Components that may be removed and serviced without exchanging the complete battery pack are identified in the bulletin/PI. Please contact the GM Technical Assistance Center if you have any questions.

Battery Charger Bus Diagnostics

  1. Vehicle OFF, disable the high voltage at the T18 Battery Charger. Refer to High Voltage Disabling .
  2. Disconnect the X7 harness connector at the A28 hybrid/EV battery contactor assembly.
  3. Disconnect the X5 harness connector at the A28 hybrid/EV battery contactor assembly.
  4. Test for infinite resistance between the terminals listed below:
    • High voltage DC (-360 V) negative terminal B X5 harness connector at the A28 hybrid/EV battery contactor assembly to vehicle chassis ground.
    • High voltage DC (+360 V) positive terminal A X5 harness connector at the A28 hybrid/EV battery contactor assembly to vehicle chassis ground.
    • High voltage DC (+360 V) positive terminal A X5 harness connector at the A28 hybrid/EV battery contactor assembly and the high voltage DC (-360 V) negative terminal B X5 harness connector at the A28 hybrid/EV battery contactor assembly.
    • If less than the specified value, replace the high voltage DC cables. After the repair is complete with a scan tool, the Clear Secured High Voltage DTCs  reset function must be performed.
  5. Test for less than 10 Ω between the terminals listed below:
    • High voltage DC (-360 V) negative terminal B X4 harness connector at the T18 Battery Charger and the high voltage DC (-360 V) negative terminal B X5 harness connector at the A28 hybrid/EV battery contactor assembly.
    • High voltage DC (+360 V) positive terminal A X4 harness connector at the T18 Battery Charger and the high voltage DC (+360 V) negative terminal A X5 harness connector at the A28 hybrid/EV battery contactor assembly.
    • If greater than the specified value, replace the high voltage DC cables. After the repair is complete with a scan tool, the Clear Secured High Voltage DTCs  reset function must be performed.
  6. If all circuits test normal, replace the T18 Battery Charger. If the DTC resets, replace the A4 hybrid/EV battery pack assembly.

Battery Main Bus Diagnostics

  1. Vehicle OFF, disable the high voltage at the T6 Power Inverter Module Assembly. Refer to High Voltage Disabling .
  2. Disconnect the F118 hybrid battery pack connector jumper connector at the A28 hybrid/EV battery contactor assembly.
  3. Disconnect the X3 harness connector at the A28 hybrid/EV battery contactor assembly.
  4. Test for infinite resistance between the terminals listed below:
    • High voltage DC (-360 V) negative terminal B X3 harness connector at the A28 hybrid/EV battery contactor assembly to vehicle chassis ground.
    • High voltage DC (+360 V) positive terminal A X3 harness connector at the A28 hybrid/EV battery contactor assembly to vehicle chassis ground.
    • High voltage DC (+360 V) positive terminal A X3 harness connector at the A28 hybrid/EV battery contactor assembly and the high voltage DC (-360 V) negative terminal B X3 harness connector at the A28 hybrid/EV battery contactor assembly.
    • If less than the specified value, replace the high voltage DC cables. After the repair is complete with a scan tool, the Clear Secured High Voltage DTCs  reset function must be performed.
  5. Test for less than 10 Ω between the terminals listed below:
    • High voltage DC (-360 V) negative terminal B X3 harness connector at the A28 hybrid/EV battery contactor assembly and the high voltage DC (-360 V) negative terminal B X3 harness connector at the T6 Power Inverter Module Assembly.
    • High voltage DC (+360 V) positive terminal A X3 harness connector at the A28 hybrid/EV battery contactor assembly and the high voltage DC (+360 V) negative terminal A X3 harness connector at the T6 Power Inverter Module Assembly.
    • If greater than the specified value, replace the high voltage DC cables. After the repair is complete with a scan tool, the Clear Secured High Voltage DTCs  reset function must be performed.
  6. If all circuits test normal, replace the T6 Power Inverter Module Assembly. If the DTC resets, replace the A4 hybrid/EV battery pack assembly.
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