EV Electrical System Troubleshooting
High-voltage diagnostics • Complex system repair • Advanced electrical testing
Advanced EV Electrical Diagnostics
Electric vehicles feature complex high-voltage electrical systems operating at 400-800V with sophisticated control networks, power distribution modules, and integrated safety systems that require specialized diagnostic equipment and expertise.
Our certified high-voltage technicians use advanced oscilloscopes, thermal imaging, and OEM diagnostic tools to troubleshoot electrical faults in Tesla, BMW, Mercedes, Ford, Rivian, and all major EV brands. From intermittent faults to complete system failures.
🚨 Emergency Electrical Issues:
- • Charging port malfunctions
- • High-voltage system faults
- • Power loss or reduced performance
- • Electrical burning smells
- • Dashboard warning lights
Diagnostic Pricing
Safety First: All high-voltage work follows OSHA safety protocols!
Comprehensive Electrical System Services
Advanced diagnostics and high-voltage electrical repair
High-Voltage Diagnostics
Advanced testing of 400-800V electrical systems
Charging Port Repair
DC fast charging and AC charging port troubleshooting
Control Module Testing
ECU diagnostics and communication network testing
Wiring Harness Service
High-voltage cable inspection and repair
Insulation Testing
Electrical insulation integrity verification
Power Distribution Service
Junction box and fuse panel diagnostics
CAN Bus Troubleshooting
Vehicle network communication diagnostics
Thermal Imaging Analysis
Heat detection for electrical component issues
Oscilloscope Testing
Advanced waveform analysis and signal testing
EV Electrical System Architecture
High-Voltage Battery
Key Components:
- • Battery management system
- • Cell monitoring
- • Thermal protection
Power Electronics
Key Components:
- • Inverter/converter
- • DC-DC converter
- • Onboard charger
Motor Controllers
Key Components:
- • Motor control unit
- • Resolver/encoder
- • Temperature sensors
Vehicle Networks
Key Components:
- • CAN high/low speed
- • LIN networks
- • Ethernet backbone
Case Study: Tesla Model 3 Charging System Fault
Resolving intermittent charging failures and high-voltage isolation fault
Problem Diagnosis
Symptoms Identified:
- • Charging stops after 5-10 minutes
- • High-voltage isolation fault alerts
- • Supercharger compatibility issues
- • Onboard charger overheating
- • Inconsistent charge port detection
Solution & Results
Services Performed:
- • High-voltage connector replacement
- • Insulation resistance testing
- • Charging system recalibration
- • Thermal imaging inspection
- • Complete system verification
Advanced Diagnostic Equipment
Professional Testing Tools
Digital Oscilloscopes
High-frequency signal analysis and waveform capture
FLIR Thermal Imaging
Heat signature detection for component failures
High-Voltage Multimeters
CAT III 1000V safety-rated measurement tools
Insulation Testers
Megohm testing for electrical safety verification
Brand-Specific Diagnostics
Electrical System FAQ
What makes EV electrical systems different?
EVs operate at high voltages (400-800V) with complex power electronics, requiring specialized safety equipment and training. Traditional 12V automotive electrical knowledge is insufficient for EV systems.
How do you safely work on high-voltage systems?
We follow strict OSHA lockout/tagout procedures, use insulated tools rated for high voltage, and verify system de-energization before beginning work. All technicians are certified for high-voltage safety.
Can electrical problems damage the battery?
Yes, electrical faults can potentially damage expensive battery systems. Early diagnosis and repair prevent cascading failures and protect your investment in the battery pack.
Why do some electrical problems seem intermittent?
Temperature changes, vibration, and moisture can cause intermittent electrical connections. Our thermal imaging and oscilloscope testing can identify these elusive faults.
How long do electrical system repairs take?
Diagnostic time varies from 2-8 hours depending on complexity. Repairs can range from same-day connector repairs to multi-day control module replacements requiring programming.
Schedule Your Electrical Diagnostics
Professional high-voltage electrical system troubleshooting
Request EV Electrical System Troubleshooting & Diagnostics
Booking requests are now handled on our Contact page.
Reach out and our team will confirm your appointment quickly.
Expert EV Electrical Diagnostics
Advanced troubleshooting for complex electrical systems