High Voltage Shut-off Procedures
• When working on high voltage system, the work should be performed by technicians who have completed the relevant training. A lack of understanding of the high voltage system can lead to serious accidents due to electric shock or electric leakage.
• When working on high voltage system or related components, make sure that you are familiar and comply with the "Safety Precautions, Cautions and Warnings." If you do not comply with the instructions, serious accidents due to electric shock or leakage may occur.
• When working on high voltage system, make sure to check the Personal Protective Equipment (PPE) and high voltage shut-off procedures.
1.Check the Battery Management System (BMS) weld flag with the KDS service data.(Data Analysis → Battery Management System (BMS) → BMS Weld Flag)
2.Open the front trunk (A).
3.Open the auxiliary battery (12 V) service cover (A).
4.Turn the IG OFF, separate the auxiliary battery (12 V) ( - ) terminal (A).
Tightening torque :7.8 - 9.8 N·m (0.8 - 1.0 kgf·m, 5.8 - 7.2 lb·ft)
5.Disconnect the service interlock connector (A).
• Wait more than 5 minutes for capacitor of the high voltage battery system to be discharged completely.
• When working on a vehicle during discharging the capacitor, it can cause an electrical shock or injury, so follow the manual.
6.Remove the front under cover.(Refer to Motor and Reduction Gear System - "Front Under Cover")
7.Remove the high voltage battery cover (A).
Tightening torque :7.8 - 11.8 N·m (0.8 - 1.2 kgf·m, 5.8 - 8.7 lb·ft)
8.Disconnect the front high voltage junction box power cable (A).
How to disconnect the connector
1)Release the locking clip (A) by pulling it.
2)Disconnect the connector by pushing the lever (A) in the direction of the arrow while pressing the locking clip (B).
9.Remove the center floor rear under cover.(Refer to Motor and Reduction Gear System - "Rear Under Cover")
10.Disconnect the Integrated Charge Control Unit (ICCU) connector (A).
1)Release the locking clip (A) by pulling it.
2)Disconnect the connector while pressing the locking clip (B).
11.Disconnect the rear high voltage junction box power cable (A).
How to disconnect the connector
1)Release the locking clip (A) by pulling it.
2)Disconnect the connector by pushing the lever (A) in the direction of the arrow while pressing the locking clip (B).
12.Measure the voltage between the high voltage power connector and high voltage battery terminal to check whether the high voltage is shut-off.
30 V or below : Normal shut-off high voltage circuitAbove 30 V : Fault on high voltage circuit
(1)Measure the voltage between the high voltage power connector positive ( + ) terminal and negative ( - ) terminal.
(2)Measure the voltage between the high voltage battery positive ( + ) and negative ( - ) terminal.
(3)Measure the voltage between the high voltage battery positive ( + ) terminal and ground.
(4)Measure the voltage between the high voltage battery negative ( - ) terminal and ground.
(5)Measure the voltage between the rear high voltage battery positive ( + ) and negative ( - ) terminal.
(6)Measure the voltage between the rear high voltage battery positive ( + ) terminal and ground.
(7)Measure the voltage between the rear high voltage battery negative ( - ) terminal and ground.
1)Check for insulation breakdown via KDS and physical leakage current before working on EV.
2)Remove the main fuse if insulation breakdown or leakage current is suspected. [Remove the main fuse even when DTC CODE ON such as Power Relay Assembly (PRA) malfunction](Refer to High Voltage Battery Control System - "Main Fuse")If there is no insulation breakdown or leakage current and it is normal, work without removing the main fuse.
