EV Diagnosis and Troubleshooting

Pre-requisites

Skills to work safely with high-voltage EV systems.
Ability to identify, test, and troubleshoot electrical and network issues.
Practical experience using industry-standard diagnostic tools.

Electrical Review
- Series Circuits
- Electrical Terms
- Parallel Circuits
- Circuit Components
- Circuit Malfunctions
- Voltage Drop
High Voltage Dangers
- Electrocution
- Orange Wires (High Voltage Identification)
- Other Electrical Dangers
- Manufacturer Procedures / Information
Personal Protection Equipment (PPE)
- Importance of Brain Awareness in Safety
- Gloves, Shoes, Face Shield
- Inspecting PPE: Date, Chemical Damage, Cuts/Abrasions, Leaks
- Manufacturer Procedures / Information
- Activity: PPE Inventory
High Voltage School Bus Systems
- Factory Training Overview
- Battery Packs
- Motor / Generator
- Inverter
- Thermal Management System
- P/S System (Power Steering)
- Air Compressor System
- HV System Distribution Compartment
- Low Voltage System
- MSD (Manual Service Disconnect)
- Electric Drive System
- Activity: Bus Walk-Around<

Electric Safety Systems
- 12V Battery
- High Voltage Interlock Loop (HVIL)
- Service Disconnects
- Manufacturer Procedures / Information
Digital Multi-Meters (DMM)
- Choosing the Right DMM
- CAT III Meter and Leads
- Verify / Use / Verify Procedure
- One-Hand Rule for Safety
- Specialty DMMs
- Fluke Training Website
Safe-Down Procedure for Electric Bus (30 min)
- Is the HV Battery Ever Fully Safe?
- What to Do, When, and How
- First Responders’ Guidelines
- Manufacturer Procedures / Information

Calculating Charge Rate and Time
Factors Affecting Charge Rate
Proximity Pilot Circuit Operation
Control Pilot Circuit Operation
Circuit Inspection and Testing Using Digital Multimeters and Digital Storage Oscilloscopes
Vehicle On-Board Chargers
Diagnosing “No-Charge” Concerns

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