DIAGNOSTIC:

Follow next steps provided within the technical service case file. Next steps may
lvary based on analysis of SDS CAN Trace.

4. Charge, discharge, and test drive of
vehicle

[2. State of Charge (SOC) calibration

3. High-voltage battery(s) replacement

If the high-voltage battery(s) require
replacement, record/document voltages
land serial #s on the proper battery detail
lform

|4. Return vehicle back to service

1. Install the Electric Vehicle "Y" Adapter Cable to the diagnostic connector(s) on the vehicle.

Figure #1: Y Cable Installation Bus |[Figure #2: Y Cable Installation eMV

Item 1: 9-pin connector Item 1: 9-pin connector
Item 2: 10-pin connector Item 2: 10-pin connector

[Nore

[10-pin connector may be cable strapped to harness |

2. Launch Navistar Service Diagnostics Solutions (SDS) Software using an Electronic Service Tool (EST)
3. Key ON, record for 3 mintues, end recording,
4. Key OFF.

5. Attach SDS CAN Trace to case file

REPAIR STEPS

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

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

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

WARNING! To prevent personal injury and / 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.

WARNING! To prevent personal injury and / 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 highvoltage
cables or high-voltage components without wearing approved highvoltage PPE.

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

1. Obtain new high voltage battery(s)

[Nore

Do not damage packaging of the new HV Battery. This packaging will be used to send
back the failed HV Battery. Refer to G-Letters within other resources for HV battery
returns

2. Perform voltage check on new high-voltage battery(s)

Figure 3: High-Voltage Battery Voltage Measurement Locations

Item 1: High-Voltage Positive Contact Slot
Item 2: High-Voltage Negative Contact Slot

3. Wearing and using approved high-voltage Personal Protective Equipment (PPE), use a category Ill digital multimeter to measure the voltage of the high-
voltage battery. Place the positive multimeter probe on the high-voltage positive contact slot (1) and the negative meter probe on the high-voltage negative
contact (2).

4, Record readings along with the serials #s of the high-voltage battery(s) on the proper battery detail form.

5. Submit the battery detail form on the case file and wait for next steps.

6. Once next steps have been defined and completed, proceed to step 7.

7. Disconnect high-voltage battery charger.

8. Bring vehicle to shop area and park vehicle on a dry level surface.

9. Turn ignition to key OFF position

10. Turn 12V disconnect switch OFF.

11. Perform high-voltage isolation level 3; refer to the proper section within the service manual

12. Perform the high-voltage battery replacement procedure for the identified failed battery(s); refer to the proper sections within the service manual.

13. Collect SDS CAN trace (refer to SDS CAN trace instructions) and attach to the case file.

14, If needed, charge vehicle up to 100% State of Charge (SOC)

15. Wait one hour after charging, then collect SDS CAN trace (refer to SDS CAN trace instructions) and attach to the case file.

16. Test drive vehicle until the SOC gauge on the cluster reads less than 40%.

17, Wait 30 minutesafter driving, then collect SDS CAN trace (refer to SDS CAN trace instructions) and attach to the case file.

18. Wait for next steps provided via case file

19. Once next steps are completed, the vehicle can be release back to service,

WARRANTY INFORMATION

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

Standard Repair Times:
Refer to the SRT Manual for Repair Times

OTHER RESOURCES

Master Service Information Site