Did the install/drive follow a 30 hour charge?

What are your tap voltages?

Why are you discharging without a full charge?

 

Sorry, didn't mean to imply I was doing a discharge. I just hooked up the charging harness and discharge harness to make sure I had the connection after the pack was in the car.
This morning I measured the pack and it's at 162.5v.
I'll hook up the grid charger and let it run for 30 hours before discharging and report back.
I truly appreciate your help and patience.

 

Did you measure tap voltages before charging or discharging?

 

I wasn't sure exactly how to measure this (or find a good diagram) on the BCM, so I didn't want to tempt fate.
With the battery pack, I only measured the voltage on the positive and negative terminals where the grid charge harness attaches before and after discharging.

 

With the IPU lid off, you probe the back of connector 7 (do not unplug it):

https://electricvehicleforums.com/fo...62/#post268612

 

I've used 2 multimeters, and am having trouble getting any sort of reading probing connector 7's back.
For some pins, I can't even get the probe to reach. Given the placement, it seems very difficult.
Should I detach the BCM to take the readings, or what am I missing?
I know I've got the correct connector.

 

You should be able to visually see the metal crimps holding the wires. it's simply a matter of contacting these with the multimeter leads. If you're timid, you'll never get a reading. I typically have to exert at least a few pounds of force to get the probes to engage with the contacts. I would estimate that I've used as much as 10# in some cases.

 

I'm putting enough pressure on the connector that I'm afraid I'll break it. It's pretty hard to get the probe into the back side of it.
Pardon my noob experience with electricity, but as this main cable is coming off the hybrid battery, wouldn't the same results be achieved (and be easier) by unplugging this connector and measuring the voltage from the front instead of the back?
And just so I'm clear, this is the connector in question below.
http://surfmypictures.com/photo/cd91..._connector.jpg

 

The picture is about 1" on my monitor, but I believe that's the correct one.

Yes, you can unplug it, but the pin holes on that side are very small and unlikely to accommodate your VM probes.

 

I was able to easily take readings from the #7 connector once it was unplugged.
First, I measured it the morning after a discharge (it was 138.8v), mindful of the fact that I'm never able to fully discharge the pack down to 60v.
14-6: 14.2
6-13: 13.9
13-5: 14.3
5-4: 14.5
1-7: 14.1
7-2: 13.8
2-8: 12.5
8-3: 13.6
3-9: 13.7
9-10: 14.2

Second measurement was after a full 30 hour charge. Battery measured 167.25v.
14-6: 16.39
6-13: 16.50
13-5: 16.97
5-4: 17.52
1-7: 16.95
7-2: 16.46
2-8: 16.22
8-3: 16.50
3-9: 16.65
9-10: 17.09

Third was the day after the full 30 hour charge (about 20 hours). Battery measured 161.50v.
14-6: 15.90
6-13: 16.01
13-5: 16.42
5-4: 16.80
1-7: 16.41
7-2: 16.01
2-8: 15.27
8-3: 16.02
3-9: 16.17
9-10: 16.53