Component

1. Upper Case Bolt
1-a. 103.0 - 154.9 N·m (10.5 - 15.8 kgf·m, 75.9 - 114.3 lb·ft)
2. O-ring
3. Watertight Bracket
3-a. 1st : 8.8 N·m (0.9 kgf·m, 6.5 lb·ft)
3-a. 2nd : 10.8 N·m (1.1 kgf·m, 8.0 lb·ft)
4. Upper Case
5. Waterproof Gasket
6. Sub Battery Pack Assembly (Sub-BPA)
6-a. 7.8 - 11.8 N·m (0.8 - 1.2 kgf·m, 5.8 - 8.7 lb·ft)
7. Battery Module Assembly (BMA)
7-a. 19.6 - 29.4 N·m (2.0 - 3.0 kgf·m, 14.5 - 21.7 lb·ft)

Special Service Tool

Tool Name / Number	Illustration	Description
High Voltage Battery Module Assembly transport hanger 09375 - GI700		Used to transferring the high voltage Sub Battery Pack Assembly (Sub-BPA)
High voltage battery module surface pressure jig 09375 - GI800		Used for compressing the high voltage Sub Battery Pack Assembly (Sub-BPA)
High voltage battery module guide 09375 - GI900		Used for seating the high voltage battery module on the surface pressure jig
High voltage battery module disassembly jig TMS - 1907		Used for disassembling the high voltage Sub Battery Pack Assembly (Sub-BPA)

Removal

   

• 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.

   

• Install the high voltage battery module surface pressure jig and guide before using the high voltage battery module disassembly jig. (Refer to the equipment manufacturer's manual)

• The procedure for removing the Battery Module Assembly (BMA) below is for #1 to 4. Other BMAs are performed in the same procedures.

1.Remove the Sub Battery Pack Assembly (Sub-BPA).(Refer to High Voltage Battery System - "Sub Battery Pack Assembly (Sub-BPA)")

2.Remove the high voltage module assembly hanger (09375 - GI700) (A).

3.Rotate the jig handle to clockwise to apply Sub-BPA (A) surface pressure.

Specified torque :4.9 - 6.9 N·m (0.5 - 0.7 kgf·m, 3.6 - 5.1 lb·ft, 43.4 - 60.8 lb·in)

4.Remove the Battery Module Assembly (BMA) (A) after removing the bolts.

Tightening torque :19.6 - 29.4 N·m (2.0 - 3.0 kgf·m, 14.5 - 21.7 lb·ft)

5.Visually inspect the underside of the BMA, and if there is any deformation, replace the BMA with a new one.

   

When using the deformed battery modules may result in fire, so replace them with new ones.

Installation

   

• 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.Perform the cell balancing procedures when the Battery Module Assembly (BMA) is replaced with a new one.(Refer to Battery Module Assembly (BMA) - "Adjustment")

2.Apply a new gap filler using the tools.(Refer to High Voltage Battery System - "Gap Filler Application")

3.Install in the reverse order of removal.

   

• Install the battery module assembly (BMA) to the specified torque.

• If the BMA is dropped, it may cause internal damage. (Do not reuse)

• When installing the BMA, tighten the bolts in the following order while pressurized.

4.Perform the High Voltage Battery Pack Connector Check with the KDS before installing the Battery System Assembly (BSA) upper case.(S/W Management → Battery Management System (BMS) → High Voltage Battery Pack Connector Check)

5.Perform the air tightness inspection with the KDS.(Refer to High Voltage Battery System - "Air Tightness Inspection")

6.Perform the SOC calibration with the KDS.(S/W management → Battery Management System (BMS) → SOC Calibration)

   

Refer to the KDS screen for operating conditions and details.

Special Service Tool

Tool Name	Illustration	Description
High voltage battery module balancer Tool & Tech T2000		Used for balancing the cell when replacing the battery module (Required to reduce voltage difference with existing battery modules when replacing the battery modules)

Adjustment

Battery Cell Balancing Procedures

1.Measure the voltage of 4 good Battery Module Assembly (BMA) by using the digital tester.

2.Calculate the target voltage using the measured value.

Target Voltage : A ÷ 4A : Sum of voltages of the 4 good battery module assemblies

   

• Do not need to calculate the maximum and minimum voltage with the KDS because the target voltage is calculated after measuring the good battery module voltage.

• Do not need to calculate the individual cell voltage because the number of all BMA is the same.

3.Perform the battery module balancing after installing the new BMA to the xEV Battery Module Balancer then putting the target voltage in it.

   

Charge/discharge the battery module after securing enough space around the xEV Battery Module Balancer.

4.Compare the new battery module voltage and the target voltage with the digital tester, after completing the BMA balancing.