contactor failure prevention strategies

Top Causes of High-Voltage Contactor Failure and Preventive Maintenance

ByJack Kilmer

Top causes of high-voltage contactor failure include arc wear, coil overheating, improper sizing, and aging contacts. Contamination and environmental factors rise contact resistance, while mechanical wear and linkage fatigue undermine operation. Inadequate sealing, breather issues, and insulation degradation compound risk. For preventive maintenance, you’ll monitor arc rate, track coil temperatures, verify inrush handling, and clean…

testing 12v battery isolation

How to Test 12V Auxiliary Battery Using Isolation Tester Safely

ByJack Kilmer

To test a 12V auxiliary battery safely with an isolation tester, begin by ensuring you have PPE, a dry, ventilated workspace, and a disconnect tool. Verify the tester’s 12V rating and inspect leads for damage. With the engine off, disconnect the negative terminal, attach clamps to clean battery posts, and power the tester in its…

diagnosing bms warning issues

How to Diagnose BMS Warning in a Battery EV Powertrain

ByJack Kilmer

To diagnose a BMS warning in an EV powertrain, start with safety and isolate the system, then collect fault codes and live data. Verify cell voltages, SOC/SOH, and pack health against specs. Check cooling system performance, coolant temps, and flow, plus sensor accuracy. Inspect CAN/PCM communication, physical layers, and error frames. Form hypotheses per subsystem—cell…

software updates improve charging

How Software Updates Can Clear Slow Charging in EVS

ByJack Kilmer

Software updates can clear slow charging by optimizing battery management, charging profiles, and thermal control. They fix issues at the connector, power source limits, and aging cells, while refining state-of-charge models to stabilize target voltages and currents. Updates recalibrate charging limits, taper points, and pause strategies, and improve charger negotiation for higher DC fast-charge percentages….

inverter maintenance and battery care

Charging Tips to Avoid Inverter Fault and Extend Battery Life

ByJack Kilmer

To avoid inverter faults and extend battery life, match your charger output to your battery type (lead-acid, gel/AGM, or lithium) and use proper charging stages (bulk, absorption, float) with safeguards like current limits and temperature compensation. Manage depth of discharge by staying within low DoD to reduce stress, and avoid deep cycles. Control temperature during…

on board charger error prevention

Top Causes of On-Board Charger Error and Preventive Maintenance

ByJack Kilmer

Top causes of On-Board Charger (OBC) errors typically include input power irregularities, communication faults, and component wear that degrades DC bus stability. You’ll also see intermittent connections, loose or corroded terminals, and firmware glitches that disrupt handshake and timing. Preventive maintenance should target wiring integrity, secure connectors, thermal management, and regular electrical tests of the…

inverter isolation testing safety

How to Test Inverter Using Isolation Tester Safely

ByJack Kilmer

To test an inverter safely with an isolation tester, start with a clear safety plan and PPE, confirming the area is isolated and de-energized. Choose a tester rated for your inverter’s voltage and insulation class, verify calibration, and inspect leads for damage. Set up a dry, uncluttered workspace, keep grounding paths clear, and document limits…

battery overheating after charging

Why Battery Thermal Management Issue Appear After Charging and How to Fix Them

ByJack Kilmer

You’ll see battery thermal issues after charging because rapid charging and charge-transfer heat raise internal resistance losses faster than they can dissipate. This signals the need for better cooling, smarter charging, and proactive maintenance. Heat spikes come from high charging currents, chemistry limits, and uneven heat distribution. Manage with slower, stage charging, improve airflow, and…

on board charger fault repair

Step-By-Step: Fixing a On-Board Charger Fault Safely

ByJack Kilmer

To fix an on-board charger fault safely, start by powering down, unplugging the charging supply, and isolating the system. Assess safety first, checking for moisture, damaged connectors, and excessive heat. Gather PPE and insulated tools, then review fault indicators against the manufacturer’s codes. Verify the input power and wiring, guarantee proper grounding, and segment the…

airbag connector corrosion prevention

Preventive Maintenance to Avoid Airbag Connector Corrosion With Airbags and ABS

ByJack Kilmer

To prevent airbag and ABS connector corrosion, you should establish a standards-driven maintenance routine that emphasizes clean, dry contacts and secure mating. Inspect for signs of moisture ingress, pitting, or coating degradation, and document findings with dates, locations, and photos. Use dedicated tools, anti-static measures, and approved cleaners, then reseat connectors and reseal as specified….

wiring faults causing fault codes

Common Wiring Faults That Cause Fault Codes After Battery Disconnect in Safety Systems

ByJack Kilmer

After a battery disconnect, you’ll likely see fault codes from loose or damaged connections, grounding or bonding lapses, insulation damage, or misrouted circuits. Check critical joints for corrosion, frayed wires, and bent pins, then reseat connectors and test under load. Verify low-resistance grounding paths and inspect bonded conductors for continuity. Trace circuits to prevent crosstalk…