Safety Precaution: Notes

Since hybrid vehicles contain a high voltage battery, if the high voltage system or vehicles are handled incorrectly, this might lead to a serious accidents like electric shock and electric leakage.

• Be sure to shut off the high voltage by removing the safety plug before performing inspection or repairing the high voltage system. (Refer to High Voltage Shutoff Procedure  )
• The responsible worker keeps the removed safety plug to prevent the plug from being connected by mistake.
• Do not keep any metal objects (watch, ring etc.) while working on the high voltage system, which it can cause serious accidents like electric shock.
• Before beginning work on the high voltage system, the worker should wear personal protective equipment to prevent safety accidents. (Refer to Personal Protective Equipment  )
• Never allow workers who are not wear personal protective equipment to touch the high voltage system. High voltage components should be covered with an insulation sheet to prevent safety accidents.
• Use insulation tools when working on the high voltage system.
• Put the removed high voltage components on the insulation mat.

Information 

• All the high voltage wiring and connectors are orange.
• A caution label for high voltage is attached to the high voltage components.
• High voltage components: High Voltage Battery Pack Assembly, Power Relay Assembly (PRA), BMS ECU, Hybrid Power Control Unit (HPCU), Hybrid Drive Motor, HSG, Electric A/C Compressor, Low DC/DC Converter (LDC), Power Cable, Electric Compressor etc.

Use Mega Ohm Tester when measuring insulation resistance of the high voltage system.

Specification : High Impedance Digital Volt / Ohm Meter (DVOM) "Category 3"

Leads and Meter rated to 1, 000 voltage.

1. Turn the ignition switch off and disconnect the auxiliary 12V battery negative (-) cable.
2. Remove the safety plug (Turning the ignition switch ON with the safety plug removed may damage the hybrid control system).
3. Wait for more than 5 minutes so that the capacitor in the high voltage system can be naturally discharged.
4. Remove the rear seat and partition tray trim (Refer to SEAT & POWER SEAT - OPTIMA HEV BD information).
5. Remove the high voltage front cover (A).

Measure the voltage between the inverter positive and negative power cable terminals.

Fig 3: Identifying High Voltage Front Cover

Courtesy of KIA MOTORS AMERICA, INC.

Below 30V: High voltage circuit properly shut

More than 30V: High voltage circuit faulty

• Check the voltage of the high voltage connector, terminal or busbar before repairing

  Below 30V: High voltage circuit properly shut

  More than 30V: High voltage circuit faulty

• Be careful not to short circuit between positive (+) and negative (-) terminals.
• Insulate the high voltage connector or terminal with an insulation tape after disconnecting
• Tighten the high voltage terminal with the specified torque.