Stop waiting for components to fail and start predicting the future of electric vehicle maintenance. Basic repairs and standard diagnostic codes are no longer enough to keep modern EVs operating at peak performance. This training session is a deep dive into high-voltage architecture, bridging the gap between component swapping and true predictive diagnostics.

Instead of waiting for a breakdown, you will learn to read subtle electrical anomalies and catch high-voltage deterioration before it triggers a shutdown. This class focuses entirely on actionable, hands-on diagnostic concepts, real-time telemetry, and seeing high-speed data in action.

Key Topics & Hands-On Demonstrations:

- High-Voltage Isolation Pinpoint Testing: Performing precise measurements between the high-voltage and low-voltage systems to quickly identify dielectric breakdown and determine exactly “who is touching who” without unnecessary teardowns.

- Motor Insulation Health Check: Evaluating stator winding phase-to-ground integrity using megohmmeters to catch dielectric breakdown early.

- Non-Intrusive Motor Bearing Testing: Connecting an oscilloscope to capture the electrical signature passing through the motor bearing, allowing you to spot fluting and mechanical wear without pulling the drive unit.

- Contactor Degradation Testing: Measuring contact resistance and voltage drop under load to identify pitted or sticking main contactors.

- Connector Bonding Testing: Low-resistance measurements to verify the integrity of high-voltage shield bonding and chassis grounds.

- Coolant Potential Testing: Checking high-voltage coolant conductivity and voltage potential to prevent electrochemical corrosion inside battery packs and drive units.

- HV Battery Static Testing: Off-load diagnostics covering cell voltage delta checks, open-circuit balancing, and module isolation.

- HV Battery Dynamic Testing: Live data logging under acceleration, regen, and charging to capture cell sag and internal resistance spikes in real time.

- Thermal Imaging Inspection: Using thermal cameras to quickly pinpoint high-resistance connections, hot contactors, and coolant blockages.

You will leave this session with the exact diagnostic workflows used by high-voltage specialists. Every student will receive the famous EV Cheat Sheets to work through hands-on labs during class and keep as a complete reference for future testing on their own.