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Countries: CANADA, UNITED STATES Document ID: !K2300007
Availability: ISIS, Bus ISIS, FleetISIS, NotSIR Revision: 2
Major System: ELECTRIC VEHICLE Created: 1/25/2022

Current Language: English

Last Modified: 8/29/2022

Josh Bowman

Knowledge Base Other Languages: NONE Author:
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Title: Electric Vehicle Charging Concerns

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Applies To: Electric Vehicles

CHANGE LOG

Please refer to the change log text box below for recent changes to this article:

18/29/2022 - Added Charging Enable & Disable Procedures to avoid operator actions inadvertently causing concerns
13/10/2022 - Added SPN 523649 FMI 2

11/25/2022 - Initial Article Release

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DESCRIPTION

This document will guide the user on how to approach diagnostics when there is a charging concern with an electric vehicle.

Operator actions can inadvertently cause false isolation faults, which will not allow the
vehicle to charge properly. Before diagnosing, please insure operator is performing the
correct charge ‘Enable & Disable’ procedures.

e Enabling a charge session procedue
e Disabling_a charge session procedure

SYMPTOMS

Diagnostic Trouble Codes & Dashboard Indicator Lights:

Description

HVESS Charge Current Limit : Data Valid
But Above Normal Operational Range -
Most Severe Level

HVESS Charge Current Limit : Current
Above Normal Or Grounded Circuit

HVESS Charge Current Limit

HVESS Charge Current Limit : Data Valid
But Above Normal Operating Range -
Moderately Severe Level

DTC/Light

SPN 8083 FMI 0

SPN 8083 FMI 6

SPN 8083 FMI 14

SPN 8083 FMI 16

SPN 8090 FMI 0

HVESS Maximum Charge Voltage Limit :
Data Valid But Above Normal Operational
Range - Most Severe Level

SPN 523530 FMI 17

HVESS Low Insulation In Driving : Data
Valid But Below Normal Operating Range

SPN 523575 FMI 31

HVESS Faulty : Condition Exists

SPN 523576 FMI 31

HVESS Faulty

SPN 523577 FMI 31

HVESS Faulty

SPN523578 FMI 7

OBC2 Fuse : Mechanical System Not
Responding Or Out Of Adjustment

SPN 523579 FMI 12

VCU - Implausible OCI Wake-Up : Bad
Intelligent Device Or Component

SPN 523630 FMI 7

OBC1 Fuse : Mechanical System Not
Responding Or Out Of Adjustment

SPN 523649 FMI 2

Charge Plug: Data Erratic, Intermittent or
incorrec

Customer Observations or Concerns:

Vehicle will not charge
Vehicle difficult to charge
Vehicle states it is charging, but state of charge (SOC) % does not increase

Charge port LED errors (Red or Yellow)
Amber Warning Lamp (AWL) illuminated

SPECIAL TOOLS / SOFTWARE

Tool Description

Tool Number

Comments

Instructions

Class 0 Electrical
Insulating Gloves
(RED Label)

Electrical Hazard
(EH) Rated Safety
Shoes or Boots

National Fire
Protection
Association (NFPA)
Category 2 Arc
Flash Protective
Clothing and Face

Shield

SERVICE PARTS INFORMATION

Part replacement is dependant on diagnostics, common parts listed below

. - 4. Quantity
Kit Description Part Number Required Notes
LAND-BASED CHARGER N/A 1 Supplier
MODULE , OBC TOP EVO 11K 4286673C91 1 OBC2
MODULE , OBC BOTTOM EVO 11K 4286672C91 1 OBC1

MODULE , ONBOARD CHARGING

INTERFACE 4210954C91 1 OCI
MODULE , SUPERVISORY CONTROL

UNIT SCU 4209406C2 1 SCU

DIAGNOSTIC STEPS

Please do not perform any diagnostics on vehicle, until land-based charger has been
ruled out. This will require customer/dealer to work with the land-based charger supplier
to inspect and/or diagnose. Once the land-based charger has been ruled out, please feel
free to open a technical service case file at this time for aid towards on vehicle
diagnostics if needed.

To prevent property damage, personal injury, and / or death, park vehicle on a hard, flat
surface, turn the engine off, set the parking brake, and install wheel chocks to prevent the
vehicle from moving in either direction.

To prevent property damage, personal injury, and / or death, if the vehicle must be raised,
do not work under the vehicle supported only by jacks. Jacks can slip or fall over.

To prevent personal injury and / or death, always wear safe eye protection when
performing vehicle maintenance.

To prevent property damage, personal injury, and / or death, keep flames or sparks away
from vehicle and do not smoke while servicing the vehicle’s batteries. Batteries expel
explosive gases.

To prevent property damage, personal injury, and / or death, remove the ground cable from the
negative terminal of the battery box before disconnecting any electrical components. Always
connect the ground cable last.

To prevent personal injury or death, NEVER service a high-voltage vehicle without
completing high-voltage safety training. Before working on vehicle, read and obey all
High-Voltage Safety and Lock-Out Tag-Out procedures and information.

To prevent personal injury or death, wear and use approved high-voltage Personal Protective
Equipment (PPE) when near a high-voltage electric vehicle. Inspect PPE before use. Do not use
gloves or other PPE with expired dates, holes, cracks or damage. NEVER touch energized orange
high-voltage cables or high-voltage components without wearing approved high-voltage PPE.

To prevent personal injury or death, read all information in the Safety Information and
High-Voltage Safety sections of the service manual.

Step Action Decision

DIAGNOSTIC:

Does the vehicle have a charging concern?

Yes. Contact land-based charger
supplier to inspect/diagnose land-based
charger. Proceed to step 2

No. No further action needed

1
Step|Action Decision
DIAGNOSTIC: Yes. No further action needed
. ; . . . ‘ale?

2 ||Did the land-based charger supplier resolve charging concern with the vehicle? No. Perform on vehicle diagnostics
using the service manual for any faults
that may be active.

Step|Action Decision

DIAGNOSTIC:

Did on vehicle diagnostics point to root cause and resolve the charging
concern?

Yes. No further action needed, release
the vehicle.

No. Open a technical service case file
for additional support providing all

information to this point.

REPAIR STEPS

1. Bring vehicle into shop and park on a flat surface

2. Shift transmission into park or neutral, set parking brake and install wheel chocks

3. Perform proper level isolation, refer to the proper section of the service manual if needed.
4. Repair vehicle based on diagnostics per the service manual

5. Verify operation, insure vehicle is accepting a charge.

6. Release vehicle back to service

WARRANTY INFORMATION

Warranty Claim Coding:
Refer to the Warranty Coding Manual for Group and Noun Codes.

Standard Repair Time(s):
Refer to the SRT Manual for Repair Times

OTHER RESOURCES

Master Service Information Site

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