Be sure to read and follow the “General Safety Information
and Caution” before doing any work related with the high voltage
system. Failure to follow the safety instructions may result in serious
electrical injuries.
1.
Carry out a visual inspection to determine whether the vehicle requires general repair or accident repair.
2.
For the general repair, repair according to the repair process of the corresponding DTC code.
3.
For the car accident repair, determine the accident type before repairing.
1) Electrical Accidents
–
Over-charge/discharge: Displays a battery over voltage
(P1B71) code /low voltage (P1B70) code (Refer to the DTC diagnosis
guide).
–
Short: Displays a high voltage short (P1B77, P1B25) codes (Refer to the DTC diagnosis guide).
Check for main fuse open circuit after shutting off the high voltage.
3.
Check the high voltage main relay for signs of melting.
4.
Measure the high voltage battery/chassis insulation resistance.
5.
Check other components.
6.
Check the DTC code in the BMS ECU.
High voltage battery insulation damaged
? Follow the measures outlined above. ?
If the high voltage battery mount is inaccessible due to trunk or door
damage, bend or cut the exterior panels without damaging the high
voltage system and carry out the inspection and repair process.
High voltage battery not damaged
DTC code
No DTC code and battery appears normal
4) Submersion
Classification
Inspection process
Inspection results
Measures
High voltage battery not submerged
1.
Perform a visual inspection (deformation, corrosion, wire coating, odor, connector).
2.
Check for main fuse open circuit after shutting off the high voltage.
3.
Check the high voltage main relay for signs of melting.
4.
Measure the high voltage battery/chassis insulation resistance.
5.
Check other components.
6.
Check the DTC code in the BMS ECU.
High voltage battery insulation damaged
Remove the high voltage battery and repair the coating/insulation.
High voltage battery not damaged
DTC code
If a DTC code occurs, perform the repair process outlined in the DTC diagnosis guide.
No DTC code and battery appears normal
Do
not replace the high voltage battery (if the battery is damaged and
must be disposed of, perform the high voltage battery disposal process).
High voltage battery submerged [Regardless of water conditions]
1.
Check for main fuse open circuit after shutting off the high voltage.
2.
Check the high voltage main relay for signs of melting.
3.
Measure the high voltage battery/chassis insulation resistance.
4.
Check the DTC code in the BMS ECU.
Carry out these measures regardless of the inspection results
Remove the high voltage battery and repair the coating/insulation.
Main Fuse Inspection
•
Be sure to read and follow the “General Safety Information
and Caution” before doing any work related with the high voltage
system. Failure to follow the safety instructions may result in serious
electrical injuries.
•
Be sure to shut off the high voltage before doing any work
related with the high voltage system(Refer to "High Voltage Shut-off
Procedure"). Failure to follow the safety instructions may result in
serious electrical injuries.
When removing the battery pack assembly to inspect the
battery system, it can be connected to vehicle by using the SST
0K918-E4100, 0K375-E4100, 0K375-E4200. Before installing the battery
system assembly, check if the battery is OK by using the SST.
Method 1
1.
Remove the safety plug.
(Refer to High Voltage Battery Control System - "Safety Plug")
2.
Measure the resistance of safety plug cable which is connected to main fuse.
Specification : Less than 1? (20°C)
Method 2
1.
Turn the ignition switch OFF and disconnect the auxiliary battery negative (-) terminal.
2.
Shut off the high voltage.
(Refer to Battery Control System - "High Voltage Shut-off Procedure")
3.
Remove the high voltage battery upper case.
(Refer to High Voltage Battery System - "Case")
4.
Remove the upper fuse box (A).
5.
Perform the electrical test of main fuse.
Specification : Less than 1? (20°C)
Checking for Welding in the High Voltage Main Relay
When removing the battery pack assembly to inspect the
battery system, it can be connected to vehicle by using the SST
0K918-E4100, 0K375-E4100, 0K375-E4200. Before installing the battery
system assembly, check if the battery is OK by using the SST.
In order to safely remove the battery pack assembly, you must
first inspect the high voltage main relay for signs of damage on
welding.
You can use Global Diagnostic System (GDS) service data to detect weld damage in the high voltage main relay.
1.
Connect the GDS to DLC.
2.
Turn the ignition switch ON.
3.
Check the BMS weld damage state in the GDS service data.
Specification : NO
•
Be sure to read and follow the “General Safety Information
and Caution” before doing any work related with the high voltage
system. Failure to follow the safety instructions may result in serious
electrical injuries.
•
Be sure to shut off the high voltage before doing any work
related with the high voltage system(Refer to "High Voltage Shut-off
Procedure"). Failure to follow the safety instructions may result in
serious electrical injuries.
1.
Shut off the high voltage.
(Refer to "High voltage Shut-off Procedures”)
2.
Remove the high voltage battery pack assembly.
(Refer to High Voltage Battery System - "Battery Pack Assembly")
3.
Remove the upper case.
(Refer to High Voltage Battery System - "Case")
4.
Remove the protect cover (A) of power relay assembly (PRA).
5.
Check for damage on welding in the high voltage main relay.
Specification : ??(20°C)
Insulation Resistance Inspection (With vehicle)
When removing the battery pack assembly to inspect the
battery system, it can be connected to vehicle by using the SST
0K918-E4100, 0K375-E4100, 0K375-E4200. Before installing the battery
system assembly, check if the battery is OK by using the SST.
The insulation status between the vehicle and the battery pack assembly can be checked on GDS or by measuring the resistance.
1.
Connect the GDS to DLC.
2.
Turn the ignition switch ON.
3.
Inspect the insulation resistance in the GDS service data.
Specified value : 300K? ~ 1000K?
•
Be sure to read and follow the “General Safety Information
and Caution” before doing any work related with the high voltage
system. Failure to follow the safety instructions may result in serious
electrical injuries.
•
Be sure to shut off the high voltage before doing any work
related with the high voltage system(Refer to "High Voltage Shut-off
Procedure"). Failure to follow the safety instructions may result in
serious electrical injuries.
1.
Shut off the high voltage.
(Refer to Battery Control System - "High Voltage Shout-off Procedure")
2.
Connect the negative (-) terminal of mega ohm meter (A) to ground of the vehicle.
For precise measuring, connect the negative (-) terminal to the parts not painted.
3.
After connecting the positive (+) terminal to positive (+) terminal of the battery, measure the resistance as follows.
(1)
Supply 500V voltage through mega ohm meter and then wait for about 1 minute to measure the stable resistance value.
(2)
Check the resistance.
Specified value : More than 2M? (20°C)
4.
After connecting the positive (+) terminal to negative (-) terminal of the battery, measure the resistance as follows.
(1)
Supply 500V voltage through mega ohm meter and then wait for about 1 minute to measure the stable resistance value.
(2)
Check the resistance.
Specified value : More than 2M? (20°C)
Insulation Resistance Inspection (With battery)
•
Be sure to read and follow the “General Safety Information
and Caution” before doing any work related with the high voltage
system. Failure to follow the safety instructions may result in serious
electrical injuries.
•
Be sure to shut off the high voltage before doing any work
related with the high voltage system(Refer to "High Voltage Shut-off
Procedure"). Failure to follow the safety instructions may result in
serious electrical injuries.
1.
Remove the high voltage battery pack assembly.
(Refer to High Voltage Battery System - "Battery Pack Assembly")
2.
Remove the upper case of high voltage battery pack assembly.
(Refer to High Voltage Battery System - "Case")
3.
Remove the protect cover (A) of power relay assembly (PRA).
4.
Connect the negative (-) terminal of mega ohm meter to lower case.
For precise measuring, connect the negative (-) terminal to the parts not painted.
5.
Connect the positive (+) terminal to high voltage battery (+, -) terminals to measure the resistance.
(1)
Connect the positive (+) terminal of mega ohm meter (A) to positive (+) terminal of PRA high voltage.
(2)
Supply 500V voltage through mega ohm meter and then wait for about 1 minute to measure the stable resistance value.
(3)
Check the reistance value.
Specified value : More than 2M? (20°C)
(1)
Connect the positive (+) terminal of mega ohm meter (B) to negative (-) terminal of PRA high voltage.
(2)
Supply 500V voltage through mega ohm meter and then wait for about 1 minute to measure the stable resistance value.
(3)
Check the reistance value.
Specified value : More than 2M? (20°C)
(1)
Connect the positive (+) terminal of mega ohm meter (A) to positive (+) terminal of PRA inverter power.
(2)
Supply the 500V voltage through mega ohm meter and then wait about 1 minutes to measure the stable resistance value
(3)
Check the reistance value.
Specified value : More than 2M? (20°C)
(1)
Connect the positive (+) terminal of mega ohm meter (A) to positive (-) terminal of PRA inverter power.
(2)
Supply 500V voltage through mega ohm meter and then wait for about 1 minute to measure the stable resistance value.
(3)
Check the reistance value.
Specified value : More than 2M? (20°C)
Handling Guide for Storing, Transporting, and Disposing of High Voltage Battery Systems
1. High voltage battery system handling process
2. Defective high voltage battery system handling / Inspection
High Voltage Shut-off Procedure
Be sure to read and follow the “General Safety Information
and Caution” before doing any work related with the high voltage
syst ...
Specification
High Voltage Shut-off Procedures
? Specification
ItemSpecificationRemarkCapacitor Voltage between the inverter terminalsLess than 30VCheckable by multi tester
High Voltage Ba ...
See also:
Rear Hub - Carrier Inspection
1.
Check the hub for cracks and the splines for wear.
2.
Check the brake disc for scoring and damage.
3.
Check ...
Notes on the suggested use of the Tire Mobility Kit
Park your car at the side of the road so that you can work with the Tire
Mobility Kit away from moving traffic.
To be sure your vehicle will not move, even when you're on fairly level
g ...
Door Scuff Trim Repair procedures
Replacement
•
Put on gloves to protect your hands.
•
When prying with a flat-tip screwdriver, wrap it with
protec ...