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…

hv battery cell imbalance fix

Why HV Battery Cell Imbalance Appear After Charging and How to Fix Them

ByJack Kilmer

Cell imbalance after charging happens because each HV battery cell has different state of charge, aging, and resistance, plus charger behavior and BMS calibration can unevenly distribute energy. Some cells hit voltage limits sooner, others lag, and temperature or SOC mismatches worsen drift. Fixes include combining passive and active balancing, calibrating sensors, and addressing aging…

coolant line repair process

Step-By-Step: Fixing a Coolant Lines for Battery Pack Fault Safely

ByJack Kilmer

You’ll methodically diagnose and safely fix a battery-pack coolant-line fault by following a structured, step-by-step procedure. Start with safety: PPE on, hazard assessment, and a clear plan. Power down, disconnect harnesses, and locate the line from reservoir to pack. Inspect for leaks, cracks, and worn clamps. Reseal or replace faulty sections, then bleed air and…

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….

thermal management pump issues

How Thermal Issues in Thermal Management Pump Cause Regenerative Braking Inconsistent and Fixes

ByJack Kilmer

Thermal issues in the pump core disrupt regenerative braking by shifting viscosity, pressure, and response timing, which makes braking torque less predictable and energy recovery uneven. When temperatures rise, pump efficiency drops and flow can drift, delaying pressure delivery and causing throttle errors. Proper thermal management—stable temperatures, minimized hotspots, and efficient cooling paths—keeps viscosity and…

certified ev technicians needed

Cost and Safety: When to Call Certified EV Technicians for Traction Motor Noise

ByJack Kilmer

If you hear traction-motor noises, don’t rush to DIY diagnosis. Start with a safety check: pull over if vibrations spike, and note if sounds change with RPM, torque, or speed. Small, normal hums can be expected, but persistent clunks, buzzing, or power loss warrant a certified EV technician. They’ll follow a structured inspection, use calibrated…

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…