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EV Battery System
Safety Precaution
Sinse Electric Vehicle contains a high voltage, battery mishandling the high voltage system or vehicle may lead to a serious accident
including electric shock and electric leakage.
• Be sure to shut off the high voltage by removing the safety plug before inspecting or repairing the high voltage system(Refer to “High
Voltage Shut-off Procedures”).
• A responsible worker should keep removed safety plugs to prevent it from being connected by mistake.
• Keep away from any metal objects (watch, ring etc.) while working on the high voltage system, as they may cause serious accidents
like electric shock.
• Before beginning to work on the high voltage system, workers should wear personal protective equipment to prevent safety accidents
(Refer to “Personal Protective Equipment”).
• At any time, do not allow workers not wearing 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.
• Place removed high voltage components on an the insulation mat.
• Check that voltage between the high voltage terminals is below 30V after removing the safety plug.
• All the high voltage wiring and connectors are in orange.
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• A caution label for high voltage is attached to the high voltage components
• High voltage components : High Voltage Battery, Power Relay Assembly (PRA), Quick Charge Relay Assembly (QRA), Motor, Power
Cable, BMS ECU, Inverter, LDC, On-Board Charger (OBC), Main Relay, Pre-charge Relay, Pre-charge resistor, Battery Current
Sensor, Safety Plug, Main Fuse, Battery Temperature Sensor, Busbar, Charge Port, A/C Compressor, Electric Power Control Unit
(EPCU), High Voltage Heater, High Voltage Heater Relay etc.
• Inform of possible danger of high voltage by placing a "high voltage caution" sign on the vehicle as in the image below.
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Personal Protective Equipment
Name Illustration Description

Insulation gloves Used when inspecting or working on the high voltage
components
[Insulation performance : 1000V / 300A or above]
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Insulation shoes
Used when inspecting or working on the high voltage

Insulation clothes
components
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Insulation helmet
Safety glasses
Used in the following cases :

• During Removal & installation or inspection of the high voltage
battery terminals or wiring, which spark might happen.
• When working on the high voltage battery pack assembly.
Face shield
All removed high voltage components are placed on an

Insulation mat
insulation mat to prevent safety accidents.
Insulation sheet is used to cover high voltage components to

Insulation sheet protect people not wearing personal protective equipment from
safety accidents.
Warning tape Used for infomring that it is dangerous to come over this line.
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Personal Protective Equipment Inspection
• Check that the personal protective equipment is not damaged.

• Check that the insulation gloves are not torn or damaged.
• Wear the insulation glove after removing moisture.
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Fold the insulation glove as above.
Fold again 3~4 times to make it airtight.
Squeeze the inflated glove to see if the glove is torn or damaged.
Caution when repairing the power cable
• When installing the high voltage terminal, insulate the terminal using insulation tape.
• Tighten the high voltage screw with specified torque.
• Be careful that the (+) terminal does not contact the (-) terminal.
Precautions when handling high voltage battery
• Battery Control System - Refer to "High Voltage Battery Handling Guide"
Precautions in case of fire in High Voltage Battery System
• Turn OFF the Button Start. Then keep the Smart Key 2m or farther away from the vehicle to prevent unintended engine start.
• If the fire is at initial stage, quickly turn OFF the Safety Plug
(refer to "High Voltage Shut-off Procedure").
• If fire broke out indoors, ventilate the area to clear out hydrogen gas.
• If fire can be put out, then do so using a CO₂ fire extinguisher. If this is not available, then use water or other types of fire extinguisher.
• CO₂has high insulation characteristics against electricity, so it is appropriate for electricity (C Rating) related fire.
• If fire cannot be put out, evacuate to a safe location, notify the fire department and do not approach the vehicle until the fire has been
extinguished.
• Turn OFF the vehicle Key in case of vehicle submersion/collision, and then exit the vehicle as quickly as possible.
Precautions in case of high voltage battery gas and/or electrolyte leakage
• Turn OFF the Button Start. Then keep the Smart Key 2m or farther away from the vehicle to prevent unintended engine start.
• If the fire is at initial stage, quickly turn OFF the Safety Plug.
(refer to "High Voltage Shut-off Procedure").
• Gas is hydrogen and alkali vapor. If the fire occurred indoor, ventilate the area immediately and evacuate to a safe location.
• If leaked liquid comes in contact with your skin, neutralize the area immediately with boron, and then clean with running water or saline
solution.
• If leaked vapor or liquid gets in your eye, immediately clean with running water, then get medical attention.
• In case of gas leakage due to high temperature, do NOT use the battery until the high voltage battery cools down to room temperature.
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Precautions when handling vehicle after an accident
• Be sure to wear insulated gloves (or rubber gloves), protective goggles, insulated suit, and insulated boots.
• Do NOT touch the bare cable when its insulation covering has been peeled.
(refer to "Precautions When Handling Power Cable")
• In case of fire on the vehicle and if the fire can be put out, then do so by using a CO₂ fire extinguisher. If this is not available, then use
water or other types of fire extinguisher.
• If more than half of the vehicle is submerged, then do not attempt to approach high voltage components, such as the Safety Plug. If such
a component must be handled, then first relocate the vehicle to a safe location, then handle the component.
• if fire broke out indoors, ventillate the area immediately and evacuate to a safe location. because the gas id hydorgen and akali fumes.
• If leaked liquid comes in contact with your skin, neutralize the area immediately with boron, and then clean with running water or saline
solution.
• If high voltage needs to be shut-off, then refer to "High Voltage Shut-off Procedure" when handling relevant components.
Preparations when servicing accident affected vehicle
• Insulated gloves (or rubber gloves), protective goggles, insulated suit, and insulated boots.
• Boric Acid Powder or Solution.
• CO₂ fire extinguisher or other fire extinguisher.
• Towel for cleaning electrolyte.
• Vinyl tape (for terminal insulation)
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• Megaohm Tester (for checking high voltage insulation resistance)
Precautions when EV is unattended for a prolonged period
• Turn OFF the Start Button. Then keep the Smart Key 2m or farther away from the vehicle to prevent unintended engine start. (This is to
prevent rapid discharging of high voltage battery from dark current.)
• If the high voltage battery state of charge (SOC) is less than 30%, then do not leave the vehicle unattended for a prolonged period.
• If the vehicle is unattended for prolonged period, then fully recharge the battery via normal charging once every 3 months to prevent the
high voltage battery SOC from becoming 0.
• When checking the auxiliary battery for discharge status or when replacing the auxiliary battery, check for problem related to high voltage
battery SOC reset.
Hybrid Vehicle Refrigerant Recovery / Charging Precautions
• Since the electric compressor uses high-voltage, POE oil with high Volumetric Resistivity Should be used.
• Do not use the same A/C recovery / charging station as conventional belt-driven compressors.
If the POE oil in the system gets mixed with PAG oil, it may result in dielectric breakdown due to decreased volumetric resistivity and
inoperative A/C compressor, disabling the A/C compressor.
EV Battery System
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 system.
Failure to follow the safety instructions may result in serious electrical injuries.
High voltage components : High Voltage Battery, Power Relay Assembly (PRA), Quick Charge Relay Assembly (QRA), Motor, Power
Cable, BMS ECU, Inverter, LDC, On-Board Charger (OBC), Main Relay, Pre-charge Relay, Pre-charge resistor, Battery Current Sensor,
Safety Plug, Main Fuse, Battery Temperature Sensor, Busbar, Charge Port, A/C Compressor, Electric Power Control Unit (EPCU), High
Voltage Heater, High Voltage Heater Relay etc.
1. Turn the ignition switch OFF and disconnect the negative (-) terminal of the auxiliary battery.
2. Remove the cover (A) on the floor carpet of the rear seat.
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3. After loosening the nut, remove the safety plug service cover (A).
Safety plug service cover mounting nut :7.8 ~ 11.8 N.m (0.8 ~ 1.2 kgf.m, 5.8 ~ 8.7 lb-ft)
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4. Remove the safety plug (A).
Remove the safety plug in the follwing order.
5. Wait at least 5 minutes or until the capacitor in the high voltage system is fully discharged.
6. Measure the voltage between the inverter terminals to check that the capacitor in the inverter is discharged completely
(1) Lift the vehicle.
(2) Remove the high voltage battery lower cover (A) by loosening the bolt.
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(3) Remove the high voltage cable (A).
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(4) Measure the voltage between the inverter terminals.
Less than 30V : High voltage circuit properly shut
More than 30V : Faulty on high voltage circuit
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If measured voltage is over 30V, check that the safety plug is removed completely. If it is is over 30V even though the safety plug
has been removerd, there may be a serious problem in the high voltage circuit. In this case, check DTC and never touch on the
high voltage system.
EV Battery System
High voltage battery system inspection guide
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).
2) Fire
Classification Inspection process Inspection results Measures

1.
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Fire outside the high Perform visual inspections (deformation, High voltage battery insulation Remove the high voltage battery
voltage battery mount corrosion, wire coating, odor, connector). damaged and repair the insulation
2. Check for main fuse open circuit after process/coating.
e.g. fire in engine shutting off the high voltage. High voltage DTC code If a DTC code occurs, comply
3. Check the high voltage main relay for battery not with DTC diagnosis guide and
signs of welding. damaged repair process.
4. Measure the high voltage battery/chassis No DTC code and Do not replace the high voltage
insulation resistance. battery appears battery (if the battery is damaged
5. Check other parts for failure. normal and must be disposed of,
perform the high voltage battery
6. Check the DTC code in the BMS ECU.
disposal process).
Fire in the high voltage 1. Perform visual inspections (deformation, High voltage battery appears Remove the service disconnect
battery mount corrosion, wire coating, odor, connector). damaged (heat, soot, etc.) plug and perform the salt water
2. Check for visible damage of the high battery disposal process.
e.g. fire in trunk voltage battery. High voltage battery insulation Remove the high voltage battery
3. Check the high voltage main relay for damaged and repair the coating/insulation.
signs of welding after shutting off the high High voltage DTC code If a DTC code occurs, perform
voltage if no visible damage is found in the battery not the repair process outlined in the
high voltage battery. damaged DTC diagnosis guide.
4. Measure the high voltage battery/chassis No DTC code and Do not replace the high voltage
insulation resistance. battery appears battery (if the battery is damaged
5. Check other parts for failure. normal and must be disposed of,
6. Check the DTC code in the BMS ECU. perform the high voltage battery
disposal process).
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3) Collision
Collision damage to 1. Perform visual inspections (deformation, High voltage battery insulation Remove the high voltage battery
areas other than the corrosion, wire coating, odor, connector). damaged and repair the coating/insulation.
high voltage battery 2. Check for main fuse open circuit after High voltage DTC code If a DTC code occurs, perform
mount shutting off the high voltage. battery not the repair process outlined in the
3. Check the high voltage main relay for damaged DTC diagnosis guide.
e.g. front/side collisions signs of melting. No DTC code and Do not replace the high voltage
4. Measure the high voltage battery/chassis battery appears battery (if the battery is damaged
insulation resistance. normal and must be disposed of,
5. Check other components. perform the high voltage battery
6. Check the DTC code in the BMS ECU. disposal process).
Collisions involving the 1. Perform visual inspections (deformation, High voltage battery insulation ⇑ Follow the measures outlined
high voltage battery corrosion, wire coating, odor, connector). damaged above.
mount 2. Check for main fuse open circuit after High voltage DTC code ※ If the high voltage battery
shutting off the high voltage. battery not No DTC code and mount is inaccessible due to
※Example) 3. Check the high voltage main relay for damaged battery appears trunk or door damage, bend or
Rear-end collision signs of melting. normal cut the exterior panels without
4. Measure the high voltage battery/chassis damaging the high voltage
insulation resistance. system and carry out the
inspection and repair process.
5. Check other components.
4) Submersion
High voltage battery not 1. Perform a visual inspection (deformation, High voltage battery insulation Remove the high voltage battery
submerged corrosion, wire coating, odor, connector). damaged and repair the coating/insulation.
2. Check for main fuse open circuit after High voltage DTC code If a DTC code occurs, perform
shutting off the high voltage. battery not the repair process outlined in the
3. Check the high voltage main relay for damaged DTC diagnosis guide.
signs of melting. No DTC code and Do not replace the high voltage
4. Measure the high voltage battery/chassis battery appears battery (if the battery is damaged
insulation resistance. normal and must be disposed of,
5. Check other components. perform the high voltage battery
disposal process).
High voltage battery 1. Check for main fuse open circuit after Carry out these measures Remove the high voltage battery
submerged shutting off the high voltage. regardless of the inspection results and repair the coating/insulation.
[Regardless of water 2. Check the high voltage main relay for
conditions] signs of melting.
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3. Measure the high voltage battery/chassis

insulation resistance.
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.
• 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 1Ω (20°C)
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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.

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Checking for Welding in the High Voltage Main Relay
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.
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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
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(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.
4. Remove the protect cover (A) of power relay assembly (PRA).
5. Check for damage on welding in the high voltage main relay.

Specification :∞Ω(20°C)
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Insulation Resistance Inspection (With vehicle)
The insulation status between the vehicle and the battery pack assembly can be checked on GDS or by measuring the resistance.
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3. Inspect the insulation resistance in the GDS service data.
Specified value :300KΩ ~ 1000KΩ
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(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 2MΩ (20°C)
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4. After connecting the positive (+) terminal to negative (-) terminal of the battery, measure the resistance as follows.
Insulation Resistance Inspection (With battery)
2. Remove the upper case of high voltage battery pack assembly.
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4. Connect the negative (-) terminal of mega ohm meter to lower case.
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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.
(3) Check the reistance value.
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(1) Connect the positive (+) terminal of mega ohm meter (B) to negative (-) terminal of PRA high voltage.
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(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
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(1) Connect the positive (+) terminal of mega ohm meter (A) to positive (-) terminal of PRA inverter power.
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Handling Guide for Storing, Transporting, and Disposing of High Voltage Battery Systems
1. High voltage battery system handling process
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2. Defective high voltage battery system handling / Inspection
Classification Item Measures

Storage Remove the service disconnect and store the battery under the same conditions as a new battery.
Undamaged Battery Transport Minimize impacts and ensure the battery does not come in contact with other parts.
Disposal Transport the battery to the designated disposer
Damaged Common Inspection 1. Voltage check(using a digital multimeter)
battery method (1) Measure the voltage between the service disconnect plug upper (+) terminal and [High
voltage battery – PRA] connecting cable (-) terminal.
→ Specification:
(2) Measure the voltage between the service disconnect plug lower (-) terminal and [High voltage
battery – PRA] connecting cable (+) terminal.
→ Specification:
(3) Measure the voltage between the high voltage battery (+) cable terminal and high voltage
battery (-) cable terminal
→Specification:240 ~ 413 V
▶ Measures: If abnormal, submerge the battery in salt water immediately to prevent fire.
2. Temperature check(using a non-contact thermometer)
(1) Check the temperature of battery case.
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(2) Check for temperature changes by measuring the temperature again after 30 minutes.
▶ Criteria: The change should be 3 °C or less and the temperature should be below 35 °C.
▶ Measures
A. If the temperature is higher than 35°C, place the battery in a cool, dry place and wait for the
battery temperature to return to 35°C.
B. If the temperature change is more than 3°C and it continues to rise, submerse the battery in
salt water immediately.
C. If the temperature continues to rise when measuring it at 30 minute intervals, submerse the
battery in salt water immediately.
3. Isolation resistance check(using a MΩ tester)
(1) Measure the isolation resistance between the power relay terminal (+) and the battery pack
cover.
(2) Measure the isolation resistance between the power relay terminal (-) and the battery pack
cover.
▶ Criteria: 2MΩ or less (at 500V)
▶ Measures: Insulate the battery using insulating materials.
(Refer to "Take insulation actions for parts that may short circuit.)
4. Take insulation actions for parts that may short circuit(Visual inspection)
(1) High voltage battery – PRA cable terminal
(2) BMS voltage sensing connector
▶ Insulation actions
A. Use the insulation tape or rubber cap to prevent short circuit to the battery pack, cells,
modules.
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B. Fix the connector terminal to prevent wiring from moving.
5. Electrolyte leakage check
A. Check for odors within 30cm of the battery pack (electrolyte odors like chemicals or acryl).
▶ Measures: Submerse the battery in salt water immediately if a smell is detected.
Damaged Remove the service disconnect plug and store the battery under the same conditions as a new
Storage
battery battery.
check Transport Minimize impacts and ensure the battery does not come in contact with other parts.
results: Transport the battery to the designated disposer; discharge it by submerging it completely in salt
normal Disposal
water and carry out the disposal procedure.
Remove the service disconnect plug; insulate all exposed terminals; place the battery in a cool, dry
Damaged
place away from volatile or combustible substances; use insulating materials (insulation tape, rubber
battery
Damaged Storage caps, etc.) or vinyl to wrap the battery; use anti-shock materials inside the box.
battery ▶ Insulation action: Refer to "Take insulation actions for parts that may short circuit.
check ▶ Packing: Abnormal battery must be packed as same as a new battery.
results:
abnormal Transport Minimize impacts and ensure the battery does not come in contact with other parts.
Transport the battery to the designated disposer; discharge it by submerging it completely in salt
Disposal
water and carry out the disposal procedure.
Voltage Check
1. Measure the voltage between the service disconnect plug upper (+) terminal and [High voltage battery –PRA] connecting cable (-) terminal.
Specification: 120 ~ 207 V
2. Measure the voltage between the service disconnect plug lower (-) terminal and [High voltage battery –PRA] connecting cable (+) terminal.
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3. Install the safety plug.
4. Measure the voltage between the high voltage battery (+) terminal and (-) terminal.
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Take insulation actions for parts that may short circuit

1. High voltage battery – PRA cable terminal
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A. Wrap insulation tape or rubber cap around (+), (-) cable terminals to prevent short circuit of the battery pack.
B. Secure the cable to the battery pack case with the insulation tape to prevent cables from moving.
2. BMS voltage sensing connector
▶ Insulation actions
A. Wrap insulation tape or rubber cap around connectors to prevent short circuit of the battery cells and modules.
B. Secure the wiring to the battery pack case with the insulation tape to prevent wiring from moving.
Discharging high voltage batteries
High voltage batteries can cause electric shock or other injuries. If the following symptoms are detected in a high voltage battery, discharge it
as soon as possible by submerging it in salt water.
- There are traces of fire or smoke.
- The voltage of the battery is abnormally high (413 V or higher).
- The temperature of the high voltage battery continues to rises abnormally.
- It smells like chemicals or acrylic, a possible sign of electrolyte leakage.
[Discharging a battery by submersing it in salt water]
1. Pour about 53 gallons (200 liters) of water into a plastic container (e.g. poly propylene) that can submerge the whole battery.
2. Add 238 pounds (108kg) of salt to the water. Stir until salt dissolves into the solution.
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[The amount of salt] = 0.538 * [The amount of water that a battery can be fully immersed]
3. Use a lift jack to submerge the high voltage battery in the salt water.
4. Leave the battery in the salt water for 12 hours before taking it out and drying it thoroughly.
The battery should be dried in a ventilated shade to avoid direct sunlight, snow and rain.
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Put only one high voltage battery in a single salt water tank.
If you discharge more than one battery, put in the battery after discharging the previous battery completely to ensure safety.
If not, unexpected accidents such as burns may occur by exothermic reaction.
EV Battery System
Specification
High Voltage Shut-off Procedures
▷ Specification
Item Specification Remark
Capacitor Voltage between the inverter
Less than 30V Checkable by multi tester
terminals
High Voltage Battery Handling Guide

▷ Specification
Safety Plug Cable Resistance (Ω) Less than 1Ω (20°C) Checkable by multi tester
Main Fuse Resistance (Ω) Less than 1Ω (20°C) Checkable by multi tester
Checking for Welding in the High voltage
NO Checkable by GDS
Main Relay
Checking for welding in the High Voltage ∞Ω(20°C) Checkable by multi tester
Main Relay
Insulation Resistance Inspection (MΩ) 300 ~ 1000 Checkable by GDS
Insulation Resistance Inspection (MΩ) More than 2MΩ (20°C) Mega Ohm tester
Check the High Voltage Battery Voltage
(V)
120 ~ 207 Checkable by multi tester
[No. 1 Module ~ No. 4 Module or No.5
Module ~ No.8 Module]
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Check the High Voltage Battery Voltage 240 ~ 413 Checkable by multi tester
(V)
[No. 1 Module ~ No. 8 Module]
High Voltage Battery System
Item Specification Note

Cell 96 -
Rated Voltage (V) 360 -
Capacity (Ah) 75 -
Energy (KWh) 27 -
Weight (kg) 203 -
Cooling System Air-cooled Forced air cooled

SOC (%) 5 ~ 95
Cell Voltage (V) 2.5 ~ 4.3
Pack Voltage (V) 240 ~ 413 Checkable by GDS
Voltage difference between cells (mV) Less than 40
Insulation resistance (KΩ) 300 ~ 1000
Insulation resistance (MΩ) More than 2 Mega Ohm tester
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High Voltage Battery Control System
BMS ECU
▷ Specification
C-CAN terminating resistance (Ω) About 60 Combined resistance (BMS ECU↔Inverter)
C-CAN terminating resistnace (Ω) About 120 BMS ECU resistance
Main Relay
▷ Specification
Item Specification
Rated Voltage (V) 450
ON Rated Ampere (A) 200
Voltage Drop (V) Less than 0.1 (200A)
Operation Voltage (V) 12
Coil
Resistance (Ω) 21.6 ~ 26.4 (20°C)

Main Relay Fixing Status NO Checkable by GDS
Main Relay Switch (-) Resistance (Ω) ∞ Checkable by multi tester
Main Relay Operation Beep "Clicking" Checkable by GDS and SST
Coil Resistance (Ω) 21.6 ~ 26.4 (20°C) Checkable by multi tester
Pre-Charge Relay
▷ Specification
Item Specification
Rated Voltage(V) 450
ON Rated Ampere(A) 10
Voltage Drop(V) Less than 0.5 (10A)
Operation Voltage(V) 12
Coil
Resistance(Ω) 104.4 ~ 127.6 (20°C)

Pre Charger Relay Operation Sound "Clicking" Checkable by GDS and SST
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Pre Charger Relay Coil Resistance (Ω) 104.4 ~ 127.6 (20°C) Checkable by multi tester
PRE-Charge Resistor
▷ Specification
Item Specification
Capacity (W) 60
Coil
Resistance (Ω) 30
Battery Current Sensor

▷ Specification
Current (A) Ouput Voltage (V)
-400(Charge) 0.5
-200 (Charge) 1.5
0 2.5
200 (Discharge) 3.5
+400 (Discharge) 4.5
Item Specifications Remark

Current Sensor Ouput Voltage (V) About 2.5 ± 0.1 Checkable by multi tester
Current Sensor Power Voltage (V) About 5 ± 0.1 Checkable by multi tester
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Main Fuse
▷ Specification
Item Specification
Rated Voltage (V) 450 (DC)
Rated Current (A) 250 (DC)

Safety Plug Cable Resistance (Ω) Less than 1 (20°C) Checkable by multi tester
Main Fuse Resistance (Ω) Less than 1 (20°C) Checkable by multi tester
Battery Temperature Sensor

▷ Specification
Temperature (°C) Resitance (KΩ) Tolerance (%)
-40 204.5 ±4.0
-30 117.8 ±3.5
- 20 70.34 ±3.0
- 10 43.43 ±2.5
0 27.63 ±2.0
10 18.07 ±1.6
20 12.11 ±1.2
30 8.303 ±1.2
40 5.813 ±1.5
50 4.149 ±1.9
60 3.013 ±2.2
70 2.225 ±2.5
Runaway Arresting Device (RAD)

▷ Specification
RAD Combined Resistance (Ω) Less than 3 (20°C) Checkable by multi tester
RAD Terminal Resistance (Ω) Less than 0.375 (20°C) Checkable by multi tester
RAD Switch Position Bottom RAD switch and visual inspection
High Voltage Battery Heater

▷ Specification
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[14 Cell LH/ RH]

Item Specification
Resistance (Ω) 26 ~ 29
[10 Cell LH/ RH]

Item Specification
High Voltage Battery Heater Relay

▷ Specification
Item Specification
ON Rated Current (A) 10
Coil
Resistance (Ω) 104.4 ~ 127.6 (20°C)

Heater Relay Switch Resistance (Ω) ∞ Checkable by multi tester
Heater Relay Operation Sound "Tik", "Tok" Checkable by GDS and SST
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Heater Relay Coil Resistance (Ω) 104.4 ~ 127.6 (20°C) Checkable by multi tester
High Voltage Battery Heater Fuse

▷ Specification
Item Specification
Current (A) 10
High Voltage Battery Heater Temperature Sensor

▷ Specification
Temperature (°C) Resistance (KΩ) Tolerance (%)
-40 204.5 ±4.0
-30 117.8 ±3.5
- 20 70.34 ±3.0
- 10 43.43 ±2.5
0 27.63 ±2.0
10 18.07 ±1.6
20 12.11 ±1.2
30 8.303 ±1.2
40 5.813 ±1.5
50 4.149 ±1.9
60 3.013 ±2.2
70 2.225 ±2.5
High Voltage Battery Cooling System

Cooling Fan
▷ Specification
Duty(%) Fan Speed(rpm)
0 0 0
1 10 900
2 20 1200
3 30 1500
4 40 1800
5 50 2100
6 60 2450
7 70 2600
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8 80 2800
9 90 3000
Inlet Temperature Sensor

▷ Specification
-40 204.5 ±4.0
-30 117.8 ±3.5
- 20 70.34 ±3.0
- 10 43.43 ±2.5
0 27.63 ±2.0
10 18.07 ±1.6
20 12.11 ±1.2
30 8.303 ±1.2
40 5.813 ±1.5
50 4.149 ±1.9
60 3.013 ±2.2
70 2.225 ±2.5
High Voltage Charging System
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ON-Board Charger (OBC)
▷ Specification
Maximum Output 6.6kW
Ouput Density 0.52kVA/ℓ
Size 327 X 367 X 105 mm
ICCB About 1.4kW
EVSE 6.6kW
▷ Specification
100kW DC 500V, 200A
50kW DC 450V, 110A
Tightening Torques
High Voltage Shut-off Procedures
Item N.m kgf.m lb-ft

Safety plug service cover mounting nut 7.8 ~ 11.8 0.8 ~ 1.2 5.8 ~ 8.7
High Voltage Battery System

Ground cable mounting bolt 7.8 ~ 11.8 0.8 ~ 1.2 5.8 ~ 8.7
High voltage battery system assembly mounting bolt 55.0 ~ 82.4 5.6 ~ 8.4 40.5 ~ 60.8
Safety plug cable assembly bracket mounting bolt 7.8 ~ 11.8 0.8 ~ 1.2 5.8 ~ 8.7
High voltage battery pack upper case mounting bolt 7.8 ~ 11.8 0.8 ~ 1.2 5.8 ~ 8.7
Battery module outlet duct mounting nut 7.8 ~ 11.8 0.8 ~ 1.2 5.8 ~ 8.7
Battery rear mounting bracket mounting bolt 7.8 ~ 11.8 0.8 ~ 1.2 5.8 ~ 8.7
High voltage positive (+) power cable mounting nut 7.8 ~ 11.8 0.8 ~ 1.2 5.8 ~ 8.7
High voltage negative (-) power cable mounting nut 7.8 ~ 11.8 0.8 ~ 1.2 5.8 ~ 8.7
Inverter busbar mounting bolt/nut 7.8 ~ 11.8 0.8 ~ 1.2 5.8 ~ 8.7
Power relay assembly mounting nut 7.8 ~ 11.8 0.8 ~ 1.2 5.8 ~ 8.7
BMS ECU mounting nut 7.8 ~ 11.8 0.8 ~ 1.2 5.8 ~ 8.7
Safety plug cable assembly mounting nut 7.8 ~ 11.8 0.8 ~ 1.2 5.8 ~ 8.7
BMS extension wiring mounting bolt 7.8 ~ 11.8 0.8 ~ 1.2 5.8 ~ 8.7
Ground bolt 7.8 ~ 11.8 0.8 ~ 1.2 5.8 ~ 8.7
High voltage connector mounting bolt 7.8 ~ 11.8 0.8 ~ 1.2 5.8 ~ 8.7
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High voltage battery pack assembly mounting bolt 7.8 ~ 11.8 0.8 ~ 1.2 5.8 ~ 8.7

High voltage power (+)(-)cable mounting nut 7.8 ~ 11.8 0.8 ~ 1.2 5.8 ~ 8.7
High voltage battery pack upper case mounting bolt 7.8 ~ 11.8 0.8 ~ 1.2 5.8 ~ 8.7
BMS ECU mounting nut 7.8 ~ 11.8 0.8 ~ 1.2 5.8 ~ 8.7
Safety plug service cover mounting nut 7.8 ~ 11.8 0.8 ~ 1.2 5.8 ~ 8.7
Safety plug cable assembly bracket mounting nut 7.8 ~ 11.8 0.8 ~ 1.2 5.8 ~ 8.7
High Voltage Battery Cooling System

Protector outlet duct panel mounting nut 7.8 ~ 11.8 0.8 ~ 1.2 5.8 ~ 8.7
Outlet cooling duct mounting bolt 7.8 ~ 11.8 0.8 ~ 1.2 5.8 ~ 8.7
Cooling fan mounting nut 7.8 ~ 11.8 0.8 ~ 1.2 5.8 ~ 8.7
Battery module outlet duct mounting nut 7.8 ~ 11.8 0.8 ~ 1.2 5.8 ~ 8.7
High Voltage Charging System
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OBC mounting bolt 9.8 ~ 11.8 1.0 ~ 1.2 7.2 ~ 8.7
Normal charge port mounting bolt 10.8 ~ 13.7 1.1 ~ 1.4 8.0 ~ 10.1
Rapid charge port mounting bolt 10.8 ~ 13.7 1.1 ~ 1.4 8.0 ~ 10.1
High Voltage Distributing System

High voltage joint box mounting bolt 7.8 ~ 11.8 0.8 ~ 1.2 5.8 ~ 8.7
Under cover mounting bolt/ nut 7.8 ~ 11.8 0.8 ~ 1.2 5.8 ~ 8.7
Protector bracket mounting nut 7.8 ~ 11.8 0.8 ~ 1.2 5.8 ~ 8.7
Cable protect mounting nut 7.8 ~ 11.8 0.8 ~ 1.2 5.8 ~ 8.7
EV Battery System
Components Location
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1. High Voltage Battery System Assembly 4. High Voltage Joint Box
2. Electronic Power Control Unit (EPCU) 5. High Voltage Cable
[LDC+Inverter+VCU] 6. Motor Assembly
3. ON-Board Charger (OBC) 7. Reduction
EV Battery System
Description and Operation

Electric vehicle is powered by transforming electric energy into kinetic energy in the motor and high voltage battery. It can be recharged by
high voltage energy via IBC or OBC. Electric motor not only has the role of driving the vehicle but also acts as an alternator to generate
electric energy used to recharge the high voltage battery by regenerative braking. Operation principles among modules are as detailed below.
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High Voltage Electricity Flow Diagram
[Start/ Acceleration/ Uphill Take-off]
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Electric energy stored in high voltage battery pack assembly is used to generate drive force from the drive motor. Electric energy is
transformed into kinetic energy and drive force is transferred to the wheels.
[Deceleration (Regenerative Braking)]

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- Drive motor is used as an alternator and uses the kinetic energy generated during deceleration to recharge electric energy in the high
voltage battery pack assembly.
- Activate: When the vehicle speed is over 10 km/h
- Not Activate: When the vehicle speed is less than 3 km/h
[Rapid Charge]
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- Charge power : 500V, 200A
- Charge Type : Direct Current (DC)
- Charge time: Approx. 25 min.
- Charge Flow Diagram : Rapid Charge Stand -> High Voltage Battery System Assembly
- Charge Volume: 80% of High Voltage Battery's SOC
[Nomal Charge]
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- Charge power: 220V, 35A
- Charge Type : Alternating Current (AC)
- Charge time: Approx. 5 hr.
- Charge Flow Diagram : Normal Charge Stand -> ON-Board Charger (OBC) -> High Voltage Battery System Assembly
- Charge Volume : 95 % of High Voltage Battery's SOC
[Indicator]
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Signal Operation
NO RefSymbol Name Description Color Illumination Control unit
Input power
Request ON when vehicle is
ready for driving.
Ready lamp
1 Green LED CAN VCU IGN1
Request to turn ON indication

Lamp when charging is
Charge complete.
2 Green LED CAN BMS IGN3
Lamp
Request to turn ON indication

Lamp when charging is in
Charge progress.
3 Red LED CAN BMS IGN3
Lamp
In case of fault as indicated

below, vehicle power output is
limited, and Lamp ON is
requested.
Power Down - Overheating, or low SOC
4 Yellow LED CAN VCU IGN1
Lamp
- Overheating and system error
- If vehicle speed is limited due
to ABS or brake system failure.
- Cooling system failure
- Request ON in case of VCU, VCU
MCU, BMS, LDC, FATC, or MCU
OBC failure is detected. BMS IGN1
Service - Turns ON at Start and then
5 Yellow LED CAN LDC
Lamp OFF after 3 seconds.
FATC
IG1 &
OBC
IGN3
6 Yellow LED CAN BMS IGN1
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LOW Battery Request Lamp ON when high

Lamp voltage battery SOC is low.
In case of 12V auxiliary battery

Auxiliary 12V discharged, recharge device
Battery failure, or recharge system
7 Red LED CAN LDC IGN1
Charge failure.
Lamp Warning Lamp ON Request
RES Lamp Request ON in case of

(RBS: regenerative brake failure.
8 Regenerative Yellow LED CAN EBS IGN1
Braking
System)
EV Battery System
System Diagram
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OBC: ON-Board Charger

QRA: Quick Charge Relay Assembly
PRA: Power Relay Assembly
EWP: Electronic Water Pump
EPCU: Electronic Power Control Unit [LDC + Inverter + VCU]
EV Battery System
Special Service Tools

Tool Name / Number Illustration Description
High Voltage Cable Used for measuring the high voltage battery system
0K918-E4100
BMS Check Connector (21pin) Used for measuring the high voltage battery system
0K375-E4100
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BMS Check Connector (8pin) Used for measuring the high voltage battery system
0K375-E4200
Insulated tool set Used for measuring or work to high voltage parts
0K375-4U000 -22EA components (Include case)
HV Battery assembly lifting fixture Removing and installing battery pack assembly
0K375-E4300
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No. Tool Name Tool Number
1 Insulated Flat Head Screwdriver-6" 0K375-4U100
2 Insulated Phillips Screwdriver-6" 0K375-4U110
3 Insulated Flat Head Screwdriver-4" 0K375-4U120
4 Insulated Phillips Screwdriver-4" 0K375-4U130
5 Insulated Spanner-8mm 0K375-4U140
10 Insulated Ratchet Wrench-3/8" 0K375-4U190
11 Insulated Ratchet Wrench-3/8" 0K375-4U200
12 Insulated Socket Extension Bar-3/8" 0K375-4U210
13 Insulated Socket-8mm 0K375-4U220
19 Insulated Nippers-6" 0K375-4U280
20 Insulated Pliers-8" 0K375-4U290
21 Insulated Cutter 0K375-4U300
22 Insulated Tool Box 0K375-4U310
Personal Protective Equipment

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Name Illustration Description

Insulation gloves components
[Insulation performance : 1000V / 300A or above]
Insulation shoes

Insulation clothes
components
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Insulation helmet
Safety glasses
Used in the following cases :

• When removing, installing or inspecting the high voltage
battery terminals or wiring where spark may happen.
• When working on high voltage battery pack assembly.
Face shield
Any removed high voltage components are placed on the

Insulation mat
insulation mat to prevent safety accidents.
Insulation sheet is used to cover high voltage components to

Insulation sheet protect people not wearing personal protective equipment from
safety accidents.
Warning tape Used to inform danger above this line.

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Commercial Tool
Tool Name Illustration Description

Battery lift table Removing and installing battery pack assembly
pack weight: 277 kg

pack size: 1647mm x 996mm x 261mm
Multi tester Measuring resistance, voltage, and resistance
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Insulation resistance tester(Multi tester) Measuring insulation resistance, voltage, and
resistance
Crane jack Removing and installing battery pack assembly
pack weight: 277 kg

pack size: 1647mm x 996mm x 261mm
EV Battery System
Basic Troubleshooting
Basic Inspection Procedure
Measuring Condition of Electronic Parts' Resistance
The measured resistance at high temperature after vehicle running may be high or low. So all resistance must be measured at ambient
temperature (20°C, 68°F), unless stated otherwise.
The measured resistance to temperature other than ambient temperature (20°C, 68°F) is for reference only.
Intermittent Problem Inspection Procedure
Sometimes the most difficult case in troubleshooting is when a problem symptom occurs but does not occur again during testing. An example
would be if a problem appears only when the vehicle is cold but has not appeared when warm. In this case, the technician should thoroughly
make out a "Customer Problem Analysis Sheet" and recreate (simulate) the environment and condition which occurred when the vehicle was
having the issue.
1. Clear Diagnostic Trouble Code (DTC).
2. Inspect connector connection, and check terminal for poor connections, loose wires, bent, broken or corroded pins, and then verify that the
connectors are always securely fastened.
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3. Slightly shake the connector and wiring harness vertically and horizontally.
4. Repair or replace the component that has a problem.
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5. Verify that the problem has disappeared with the road test.
● Simulating Vibration
1) Sensors and Actuators
: Slightly vibrate sensors, actuators or relays with finger.
Strong vibration may break sensors, actuators or relays

2) Connectors and Harness
: Lightly shake the connector and wiring harness vertically and then horizontally.
● Simulating Heat
1) Heat components suspected of causing the malfunction with a hair dryer or other heat source.
• DO NOT heat components to the point where they may be damaged.

• DO NOT heat the ECM directly.
● Simulating Water Sprinkling
1) Sprinkle water onto vehicle to simulate a rainy day or a high humidity condition.
DO NOT sprinkle water directly into the engine compartment or electronic components.
● Simulating Electrical Load
1) Turn on all electrical systems to simulate excessive electrical loads (Radios, fans, lights, rear window defogger, etc.).
Connector Inspection Procedure

1. Handling of Connector
A. Never pull on the wiring harness when disconnecting connectors.
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B. When removing the connector with a lock, press or pull locking lever.
C. Listen for a click when locking connectors. This sound indicates that they are securely locked.
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D. When a tester is used to check for continuity, or to measure voltage, always insert tester probe from wire harness side.
E. Check waterproof connector terminals from the connector side. Waterproof connectors cannot be accessed from harness side.
• Use a fine wire to prevent damage to the terminal.

• Do not damage the terminal when inserting the tester lead.
2. Checking Point for Connector
A. While the connector is connected:
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Hold the connector, check connecting condition and locking efficiency.

B. When the connector is disconnected:
Check for missed terminal, crimped terminal or broken core wire by slightly pulling the wire harness.
Visually check for rust, contamination, deformation and bend.
C. Check terminal tightening condition:
Insert a spare male terminal into a female terminal, and then check terminal tightening conditions.
D. Pull lightly on individual wires to ensure that each wire is secured in the terminal.
3. Repair Method of Connector Terminal

A. Clean the contact points using air gun and/or shop rag.
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Never use sand paper when polishing the contact points, otherwise the contact point may be damaged.
B. In case of abnormal contact pressure, replace the female terminal.
Wire Harness Inspection Procedure

1. Before removing the wire harness, check the wire harness position and crimping in order to restore it correctly.
2. Check whether the wire harness is twisted, pulled or loosened.
3. Check whether the temperature of the wire harness is abnormally high.
4. Check whether the wire harness is rotating, moving or vibrating against the sharp edge of a part.
5. Check the connection between the wire harness and any installed part.
6. If the covering of wire harness is damaged; secure, repair or replace the harness.
Electrical Circuit Inspection Procedure

● Check Open Circuit
1. Procedures for Open Circuit
A. Continuity Check
B. Voltage Check
If an open circuit occurs (as seen in [FIG. 1]), it can be found by performing Step 2 (Continuity Check Method) or Step 3 (Voltage Check
Method) as shown below.
2. Continuity Check Method
When measuring the resistance, lightly shake the wire harness up and down or left to right.
Specification (Resistance)
1Ω or less → Normal Circuit
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1MΩ or Higher → Open Circuit

A. Disconnect connectors (A), (C) and measure resistance between connectors (A) and (C) as shown in [FIG. 2].
In [FIG.2.] the measured resistance of lines 1 and 2 is higher than 1MΩ and below 1 Ω respectively. Specifically, the open circuit is line
1 (Line 2 is normal). To find the exact break point, check sub line of line 1 as described in the following step.
B. Disconnect connector (B), and measure the resistance between connectors (C) and (B1) and between (B2) and (A) as shown in [FIG.
3].
In this case the measured resistance between connectors (C) and (B1) is higher than 1MΩ and the open circuit is located between
terminal 1 of connector (C) and terminal 1 of connector (B1).
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3. Voltage Check Method
A. With each connector still connected, measure the voltage between the chassis ground and terminal 1 of each connectors (A), (B) and
(C) as shown in [FIG. 4].
The measured voltages of each connector are 5V, 5V and 0V respectively. So the open circuit is located between connectors (C) and
(B).
● Check Short Circuit

1. Test Method for Short to Ground Circuit
A. Continuity Check with Chassis Ground
If short to ground circuit occurs as shown in [FIG. 5], the broken point can be found by performing Step 2 (Continuity Check Method with
Chassis Ground) as shown below.
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2. Continuity Check Method (with Chassis Ground)
Lightly shake the wire harness up and down or left to right when measuring the resistance.
Specification (Resistance)
1Ω or less → Short to Ground Circuit
1MΩ or Higher → Normal Circuit
A. Disconnect connectors (A), (C) and measure the resistance between connector (A) and Chassis Ground as shown in [FIG. 6].
The measured resistance of line 1 and 2 in this example is below 1 Ω and higher than 1MΩ respectively. Specifically, the short to
ground circuit is line 1 (Line 2 is normal). To find exact broken point, check the sub line of line 1 as described in the following step.
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B. Disconnect connector (B), and measure the resistance between connector (A) and chassis ground, and between (B1) and chassis
ground as shown in [FIG. 7].
The measured resistance between connector (B1) and chassis ground is 1Ω or less. The short to ground circuit is between terminal 1
of connector (C) and terminal 1 of connector (B1).
● Testing For Voltage Drop

This test checks for voltage drop along a wire or through a connection or a switch.
1) Connect the positive lead of a voltmeter to the end of the wire (or to the side of the connector or switch) closest to the battery.
2) Connect the negative lead to the other end of the wire. (or the other side of the connector or switch)
3) Operate the circuit.
4) The voltmeter will show the difference in voltage between the two points. A difference, or drop of more than 0.1 volts (50mV in 5V circuits),
may indicate a problem. Check the circuit for loose or dirty connections.
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EV Battery System
Components
High Voltage Battery System Assembly
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1. High Voltage Battery System Assembly 4. Case

2. High Voltage Battery Pack Assembly 5. QRA (Quick Charge Relay Assembly)
3. PRA (Power Relay Assembly)
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EV Battery System
Description
- To provide the 360V high voltage electric energy to electric motor
- To save the electric energy generated by regenerative braking system
- Charged by rapid charge or normal charge
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High Voltage Battery Pack Assembly
Type : Lithium Ion Polymer
Cell : Minimum unit which saves the electric energy converted from the chemical energy
Module : A number of cells in series
Pack : A number of modules in series
EV Battery System
System Diagram
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System Circuit Diagram
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EV Battery System
Inspection
0K375-E4100, 0K375-E4200.
[Battery Pack Assembly Inspection]
Specification Method Countermeasure

Disconnection - Visual check -
Rust
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Discolor
Installation status
Leak
DTC about BMS ECU Refer to DTC guide Refer to DTC guide Refer to DTC guide
Check the "Current Data" by Refer to "SOC level and the countermeasure
SOC 5% ~ 95%
GDS
Cell 2.5 ~ 4.3 V
Pack 240 ~ 413 V Check the "Current Data" by Check the battery voltage sensing circuit (Refer to
Voltage
Difference GDS "Battery voltage sensing circuit")
less than 40mV
between cells
Check the "Current Data" by
300KΩ ~ 1000KΩ
GDS
Insulation resistance Refer to "Insulation resistance circuit"
more than 2MΩ Using mega ohm tester
more than 2MΩ Using mega ohm tester
SOC (State Of Charge) - The percentage of battery charging status

[Visual Inspection]
Item - Electric System, Cooling System, High Voltage Battery Pack Assembly
Problem - Disconnection, Rust, Component status, Oil leak
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[SOC Inspection ]
1. Turn the ignition OFF.
3. Turn the ignition ON.
4. Check the SOC in the GDS service data.
SOC: 5 ~ 95 %
[Battery Voltage Inspection]

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4. Check the Cell Voltage and the Pack Voltage in the GDS service data.
Cell Voltage : 2.5 ~ 4.3 V
Pack Voltage: 240 ~ 413 V
Voltage gap between cells : Less than 40 mV
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[Voltage sensing circuit Inspection]
2. Remove the wiring harness of the voltage & temperature sensor.
(Refer to High Voltage Battery System - Repair procedures - Disassembly - "Wiring harness of the voltage & temperature sensor")
3. Perform the current test of battery module and the BMS ECU connector.
Specified value :Less than 1Ω (20°C)
4. Install the BMS ECU to lower case.

5. Install the wiring harness of voltage & temperature sensor to BMS ECU.
6. Measure the insulation resistance between the battery module harness and the lower case.
Specifed value :More than 1MΩ (20°C)
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[Insulation Resistance Inspection (With vehicle)]

The insulation status between the vehicle and the battery pack assembly can be checked by GDS or measuring the resistance.
[GDS - Service data]
1. Turn the ignition switch OFF.
Specified value :300kΩ ~ 1000kΩ
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[By using the Mega Ohm Tester]
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[Insulation resistance of positive (+) terminal of the battery pack assembly
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[Insulation resistance of negative (-) terminal of the battery pack assembly]
Specified value : More thanSpecified value : More than 2MΩ (20°C)
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[Insulation Resistance Inspection (With battery)]

[By using the Mega Ohm Tester]
2. Remove the upper case of high voltage battery pack assembly.
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4. Connect the negative (-) terminal of mega ohm meter to lower case.
5. Connect the positive (+) terminal to high voltage battery terminals to measure the resistance.
[Insulation resistance of positve (+) terminal of PRA high voltage]
(1) Connect the positive (+) terminal of mega ohm meter (A) to positive (+) terminal of PRA high voltage.
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[Insulation resistance of negative (-) terminal of PRA high voltage]
(1) Connect the positive (+) terminal of mega ohm meter (B) to negative (-) terminal of PRA high voltage.
[Insulation resistance of positive (+) terminal of PRA inverter power]

(1) Connect the positive (+) terminal of mega ohm meter (A) to positive (+) terminal of PRA inverter power.
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[Insulation resistance of positive (-) terminal of PRA inverter power]
(1) Connect the positive (+) terminal of mega ohm meter (A) to positive (-) terminal of PRA inverter power.
EV Battery System
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Removal
1. Turn the ignition swtich OFF and disconnect the auxiliary battery negative (-) terminal.
2. Shut off the high voltage. ("Refer to "High Voltage Shut-off Procedure")
3. Lift the vehicle.
4. After loosening the nut, remove the high voltage battery front under cover (A).
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5. After loosening the nut, remove the high voltage rear under cover (A).
6. Disconnect the BMS connector (A).
7. Disconnect the high voltage cable (A).

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8. Disconnect the ground cable (B) by loosening the mounting bolt (A).
Ground cable mounting bolt:7.8 ~ 11.8 N.m (0.8 ~ 1.2 kgf.m, 5.8 ~ 8.7 lb-ft)
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9. Support the high voltage battery pack assembly with the jack (A).
• Securely support the battery pack assembly with a jack to prevent any accidents.
• Confirm that high voltage cable & connectors are completely removed before removing the battery pack assembly.
• Place rubber on the jack to protect the lower part of the battery pack and the stud bolts used to tighten the under cover.
10. Loosen the high voltage battery system assembly mounting bolt (A).
High voltage battery system assembly mounting bolt:54.9 ~ 82.4 N.m (5.6 ~ 8.4 kgf.m, 40.5 ~ 60.8 lb-ft)
[Front]
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[Right]
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[Left]
[Back]
11. Remove the high voltage battery system assembly (A) from the vehicle.
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Disassembly
1. Remove the high voltage battery system assembly.
(Refer to High Voltage Battery System - Battery Pack Assembly - Repair procedures - "Removal")
2. Remove the ground cable (B) by loosening the mounting bolt (A).
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[Right]
[Left]
3. Remove the safety plug cable assembly bracket mounting bolt (A).
Safety plug cable assembly bracket mounting bolt:7.8 ~ 11.8 N.m (0.8 ~ 1.2 kgf.m, 5.8 ~ 8.7 lb-ft)
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4. After loosening the mounting bolt, remove the upper case (A).
High voltage battery pack upper case mounting bolt:7.8 ~ 11.8 N.m (0.8 ~ 1.2 kgf.m, 5.8 ~ 8.7 lb-ft)
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5. Remove the waterproof gasket (A).
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6. Disconnect the RAD wiring connector (A).
[Right]
[Back]
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[Left]
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7. After loosening the mounting nut, remove the battery module outlet duct (A).
Battery module outlet duct mounting nut :7.8 ~ 11.8 N.m (0.8 ~ 1.2 kgf.m, 5.8 ~ 8.7 lb-ft)
8. After loosening the mounting bolt, remove the bracket (A).

Battery rear mounting bracket mounting bolt:7.8 ~ 11.8 N.m (0.8 ~ 1.2 kgf.m, 5.8 ~ 8.7 lb-ft)
9. Remove the high voltage power cable cover (A).

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10. After loosening the mounting nut (A), remove the high voltage positive (+) power cable (B)
High voltage positive (+) power cable mounting nut:7.8 ~ 11.8 N.m (0.8 ~ 1.2 kgf.m, 5.8 ~ 8.7 lb-ft)
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11. After loosening the mounting nut (A), remove the high voltage negative (-) power cable (B).
High voltage negative (-) power cable mounting nut:7.8 ~ 11.8 N.m (0.8 ~ 1.2 kgf.m, 5.8 ~ 8.7 lb-ft)
12. Remove the inverter busbar cover (A).
13. Remove the inverter busbar (A).

Inverter busbar mounting bolt/nut:7.8 ~ 11.8 N.m (0.8 ~ 1.2 kgf.m, 5.8 ~ 8.7 lb-ft)
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14. Disconnect the high voltage battery heater system control positive (+) power and the ground connetor (A). [With high voltage battery
heater system]
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15. Dsiconnect the power relay assembly connector (A).
16. After loosening the mounting nut, remove the power relay assembly (A).
Power relay assembly mounting nut:7.8 ~ 11.8 N.m (0.8 ~ 1.2 kgf.m, 5.8 ~ 8.7 lb-ft)
17. Disconnect the BMS ECU connector (A).

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18. After loosening the mounting nut, remove the BMS ECU (A).
BMS ECU mounting nut:7.8 ~ 11.8 N.m (0.8 ~ 1.2 kgf.m, 5.8 ~ 8.7 lb-ft)
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19. Disconnect the safety plug interlock connector (A).
20. After loosening the mounting nut (A), remove the safety plug cable assembly (B).
Safety plug cable assembly mounting nut:7.8 ~ 11.8 N.m (0.8 ~ 1.2 kgf.m, 5.8 ~ 8.7 lb-ft)
21. Loosen the BMS extension wiring mounting bolt (A).

BMS extension wiring mounting bolt:7.8 ~ 11.8 N.m (0.8 ~ 1.2 kgf.m, 5.8 ~ 8.7 lb-ft)
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22. After loosening the ground bolt (A), remove the BMS extension wiring (B).
Ground bolt:7.8 ~ 11.8 N.m (0.8 ~ 1.2 kgf.m, 5.8 ~ 8.7 lb-ft)
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23. After disconnecting the interlock switch connector (A) and loosening the mounting bolt (B), remove the high voltage connector (C).
High voltage connector mounting bolt:7.8 ~ 11.8 N.m (0.8 ~ 1.2 kgf.m, 5.8 ~ 8.7 lb-ft)

(1) Remove the high voltage battery pack assembly mounting bolt.
High voltage battery pack assembly mounting bolt :7.8 ~ 11.8 N.m (0.8 ~ 1.2 kgf.m, 5.8 ~ 8.7 lb-ft)
(2) Install the SST No. 0K375-E4300 (A) in battery pack assembly as shown in the image below.
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Be sure to screw the eye bolts to the holes firmly not to allow the bolts to be loosened while lifting the battery pack assembly
using a crane jack.
(3) Install the SST No. OK375-E4300 (A) to crane jack.
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(4) Install the SST No. OK375-E4300 & crane jack (A).
• Make sure that the hanger hooks and the eye bolts aligns.
• Adjust the hanger main frame to fit the size of the battery pack assembly.
(5) Remove the high voltage battery pack assembly (A).
Make sure that the battery pack assembly is balanced.

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The battery pack assembly is divided into LH / RH battery pack so be sure to remove the battery one by one. The order of removal
is not important.
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25. After loosening the harness mounting screw, remove the voltage & temperature sensor wiring harness (A) from the battery pack
assembly.
[LH]
[RH]
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A/S unit
BMS ECU
Refer to High Voltage Battery Control System - "BMS ECU"
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High Voltage Battery Pack Assembly
Refer to High Voltage Battery System - "Battery Pack Assembly"
Power Relay Assembly (PRA)

Refer to High Voltage Battery System - "Power Relay"
Inverter Busbar
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Inverter busbar mounting bolt/nut :7.8 ~ 11.8 N.m (0.8 ~ 1.2 kgf.m, 5.8 ~ 8.7 lb-ft)
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BMS Wiring Harness
1. Remove the BMS ECU
(Refer to High Voltage Battery Control System - "BMS ECU")
2. Remove the power relay assembly (PRA).
(Refer to High Voltage Battery System - "Power Relay Assembly")
3. Loosen the BMS extension wiring mounting bolt (A).
BMS extension wiring mounting bolt :7.8 ~ 11.8 N.m (0.8 ~ 1.2 kgf.m, 5.8 ~ 8.7 lb-ft)
4. After loosening the mounting bolt (A), remove the BMS extension wiring (B).
Ground bolt :7.8 ~ 11.8 N.m (0.8 ~ 1.2 kgf.m, 5.8 ~ 8.7 lb-ft)
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Safety Plug Cable
Refer to High Voltage Battery Control System - Safety Plug - "Safety Plug Cable"
Front Case Left Panel

(Refer to High Voltage Battery System - "Power Relay Assembly")
2. Remove the front case left panel.
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Safety Plug Bracket

(Refer to High Voltage Battery Control System - "High Voltage Shut-off Procedure")
2. After loosening the mounting bolt (A), remove the safety plug bracket (B).
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High Voltage Connector Assembly
(Refer to High Voltage Battery System - Case - "Upper Case")
2. After disconnecting the interlock switch connector (A) and loosening the mounting bolt (B), remove the high voltage connector (C).
High voltage connector mounting bolt :7.8 ~ 11.8 N.m (0.8 ~ 1.2 kgf.m, 5.8 ~ 8.7 lb-ft)
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Battery Rear Mounting Bracket

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3. After loosening the mounting bolt (A), remove the bracket (B).
Battery rear mounting bracket bolt :7.8 ~ 11.8 N.m (0.8 ~ 1.2 kgf.m, 5.8 ~ 8.7 lb-ft)
Watertight Rainforcement Bracket

(Refer to High Voltage Battery System - Repair procedures - "Removal")
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2. After loosening the mounting bolt & nut, remove the watertight rainforcement bracket (A).
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High Voltage Battery System Rear Mounting Bracket
2. Loosen the high voltage battery system rear mounting bracket bolt (A).
High voltage battery system rear mounting bracket bolt :54.9 ~ 82.4 N.m (5.6 ~ 8.4 kgf.m, 40.5 ~ 60.8 lb-ft)
3. Loosen the rear mounting bolt (A).

High voltage battery system rear mounting bracket bolt :54.9 ~ 82.4 N.m (5.6 ~ 8.4 kgf.m, 40.5 ~ 60.8 lb-ft)
4. Remove the high voltage battery system rear mounting bracket (A).
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Battery Voltage & Temperature Sensor Wiring Harness

(Refer to High Voltage Battery System - "High Voltage Battery Pack Assembly")
2. After loosening the harness mounting screw, remove the voltage & temperature wiring harness (A) from the high voltage battery pack
assembly.
[LH]
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[RH]
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High Voltage Positive (+) Power Cable
2. Disconnect the high voltage power cable cover (A).
3. After loosening the mounting nut, remove the high voltage positive (+) power cable (A).
High voltage positive (+) power cable mounting nut :7.8 ~ 11.8 N.m (0.8 ~ 1.2 kgf.m, 5.8 ~ 8.7 lb-ft)
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High Voltage Negative (-) Power Cable
2. Disconnect the high voltage power cable cover (A).
3. After loosening the mounting nut, remove the high voltage negative(-) power cable (A).
High voltage negative (-) power cable mounting nut : 7.8 ~ 11.8 N.m (0.8 ~ 1.2 kgf.m, 5.8 ~ 8.7 lb-ft)
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Battery Module Outlet Duct

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Safety Plug
Refer to High Voltage Battery Control System - "Safety Plug"
High Voltage Battery Pack Lower Case

Refer to High Voltage Battery System - Case - "Lower Case"
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High Voltage Battery Pack Upper Case

Refer to High Voltage Battery System - Case - "Upper Case"
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Installation
When installing the RAD harness, be sure to check if the connector is installed on the correct position.
[If not correct]
1. Failure of precharging
2. RAD malfunction (misrecognize that the high voltage battery is swollen)
[Main inspection items]
1. Check if the RAD switch faces down.
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2. Be careful not to reverse battery No. 1 module RAD connector (2 pins) and the BMS extension connector (1 pin) when assembling.
3. Be careful not to reverse battery No. 8 module RAD connector ( 2 pins) and the BMS extension connector (1 pin) when assembling.
1. Install the high voltage battery system and the related parts in the reverse order of removal.
EV Battery System
Specification
Cell 96 -
Rated Voltage (V) 360 2 Cells are parallel connected
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Capacity (Ah) 75 -
Energy (KWh) 27 -
Weight (kg) 203 -
Cooling System Air-cooled Forced air cooled

SOC (%) 5 ~ 95
Cell Voltage (V) 2.5 ~ 4.3
Pack Voltage (V) 240 ~ 413 Checkable by GDS
Voltage difference between cells (mV) Less than 40
Insulation resistance (KΩ) 300 ~ 1000
Insulation resistance (MΩ) More than 2 Mega Ohm tester
EV Battery System
Components
Without High Voltage Heater System
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1. High Voltage Battery Pack Assembly 4. Inlet Temperature Sensor

2. Runaway Arresting Device (RAD) 5. Voltage & Temperature Sensor Wiring Harness
3. Busbar 6. Bolt
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With High Voltage Heater System
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1. High Voltage Battery Pack Assembly 5. Voltage & Temperature Sensor Wiring Harness
2. Runaway Arresting Device (RAD) 6. Bolt
3. Busbar 7. High Voltage Battery Heater
4. Inlet Temperature Sensor 8. High Voltage Battery Heater Temperature Sensor
EV Battery System
Inspection
[SOC Inspection ]
4. Check the SOC in the GDS service data.
SOC:5% ~ 95%
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[Battery Voltage Inspection]
4. Check the Cell Voltage and the Pack Voltage in the GDS service data.
Cell Voltage:2.5V ~ 4.3V
Pack Voltage:240V ~ 413V
Voltage gap between cells :Less than 40 mV
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[Insulation Resistance Inspection (By using the GDS)]

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Specified value:300KΩ ~ 1000KΩ
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[Insulation Resistance Inspection (By using the Mega Ohm Tester)]
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Removal
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Safety plug cable assembly bracket mounting bolt :7.8 ~ 11.8 N.m (0.8 ~ 1.2 kgf.m, 5.8 ~ 8.7 lb-ft)
High voltage battery pack upper case mounting bolt :7.8 ~ 11.8 N.m (0.8 ~ 1.2 kgf.m, 5.8 ~ 8.7 lb-ft)
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4. Disconnect the RAD wiring connector (A).
[Right]
[Back]
[Left]
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6. After loosening the mounting bolt, remove the bracke (A).
Battery rear mounting bracket mounting bolt :7.8 ~ 11.8 N.m (0.8 ~ 1.2 kgf.m, 5.8 ~ 8.7 lb-ft)
7. Remove the high voltage power cable cover (A).
8. After loosening the mounting nut (A), remove the high voltage positive (+) power cable (B)
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High voltage negative (-) power cable mounting nut :7.8 ~ 11.8 N.m (0.8 ~ 1.2 kgf.m, 5.8 ~ 8.7 lb-ft)
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Inverter busbar mounting bolt/nut :7.8 ~ 11.8 N.m (0.8 ~ 1.2 kgf.m, 5.8 ~ 8.7 lb-ft)
12. Disconnect the high voltage battery heater system control positive (+) power and the ground connector (A).
[With high voltage battery heater system]
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13. Dsiconnect the power relay assembly connector (A).
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14. After loosening the mounting nut, remove the power relay assembly (A).
Power relay assembly mounting nut :7.8 ~ 11.8 N.m (0.8 ~ 1.2 kgf.m, 5.8 ~ 8.7 lb-ft)
15. Disconnect the BMS ECU connector (A).
16. After loosening the mounting nut, remove the BMS ECU (A).
-BMS ECU mounting nut :7.8 ~ 11.8 N.m (0.8 ~ 1.2 kgf.m, 5.8 ~ 8.7 lb-ft)
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17. Disconnect the safety plug interlock connector (A).
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18. After loosening the mounting nut (A), remove the safety plug cable assembly (B).
Safety plug cable assembly mounting nut :7.8 ~ 11.8 N.m (0.8 ~ 1.2 kgf.m, 5.8 ~ 8.7 lb-ft)
19. After loosening the ground bolt (A), remove the BMS extension wiring (B).
Ground bolt: 7.8 ~ 11.8 N.m (0.8 ~ 1.2 kgf.m, 5.8 ~ 8.7 lb-ft)

(1) Remove the high voltage battery pack assembly mounting bolt.
High voltage battery pack assembly mounting bolt :7.8 ~ 11.8 N.m (0.8 ~ 1.2 kgf.m, 5.8 ~ 8.7 lb-ft)
(2) Install the SST No. 0K375-E4300 (A) in battery pack assembly as shown in the image below.
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Be sure to screw the eye bolts to the holes firmly not to allow the bolts to be loosened while lifting the battery pack assembly
using a crane jack.
(3) Install the SST No. OK375-E4300 (A) to crane jack.
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(4) Install the SST No. OK375-E4300 & crane jack (A).
• Make sure that the hanger hooks and the eye bolts align.
• Adjust the hanger main frame to fit the size of the battery pack assembly.
(5) Remove the high voltage battery pack assembly (A).
Make sure that the battery pack assembly is balanced.

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The battery pack assembly is divided into LH / RH battery pack so be sure to remove the battery one by one. The order of removal
is not important.
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21. After loosening the harness mounting screw, remove the voltage & temperature sensor wiring harness (A) from the battery pack
assembly.
[LH]
[RH]
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Installation
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[If not correct]
1. Check if the RAD switch faces down
2. Be careful not to reverse battery No. 1 module RAD connector (2 pins) and the BMS extension connector (1 pin) when assembling.
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3. Be careful not to reverse battery No. 8 module RAD connector ( 2 pins) and the BMS extension connector (1 pin) when assembling.
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1. Install the high voltage battery pack assembly in the reverse order of removal.
EV Battery System
Description
Power relay assembly (PRA) is installed in the high voltage battery system assembly and it consists of main relays which control the high
voltage, pre-charge relay, pre-charge resister and battery current sensor. PRA controls high voltage of 360V between the high voltage battery
pack and the high voltage joint box by BMS ECU control signal.
Operation
EV Battery System
Removal
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1. Remove the high voltage battery assembly.
2. Loosen the safety plug cable assembly bracket mounting bolt (A).
3. After loosening the mounting bolt, remove the high voltage battery pack upper case (A).
High voltage battery pack upper case mounting bolt :7.8 ~ 11.8 N.m (0.8 ~ 1.2 kgf.m, 5.8 ~ 8.7 lb-ft)
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4. Remove the high voltage power cable cover (A) and the inverter busbar cover (B).
5. After loosening the mounting nut (A), remove the high voltage positive (+) power cable (B).
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High voltage negative (-) power cable mounting nut :7.8 ~ 11.8 N.m (0.8 ~ 1.2 kgf.m, 5.8 ~ 8.7 lb-ft)
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7.8 ~ 11.8 N.m (0.8 ~ 1.2 kgf.m, 5.8 ~ 8.7 lb-ft)Inverter busbar mounting bolt/nut : 0.8 ~ 1.2 kgf.m
8. Disconnect the high voltage battery heater system control positive (+) power and the ground connector (A).
[With the high voltage battery heater system]
9. Disconnect the power relay assembly connector (A).

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10. After loosening the mounting nut (A), remove the power relay assembly (B).
Power relay assembly mounting nut :7.8 ~ 11.8 N.m (0.8 ~ 1.2 kgf.m, 5.8 ~ 8.7 lb-ft)
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Installation
1. Install the power relay assembly in the reverse order of removal.
EV Battery System
Description
Quick Charge Relay Assembly (QRA) is installed in the high voltage joint box and it consists of main relays which control the high voltage. The
QRA controls the high voltage between the high voltage battery pack and the high voltage joint box by BMS control signal. If the QRA
operates, the PRA operates too.
[Main Function]
1. During rapid charge, it acts as a switch that supplies high voltage to the battery pack.
2. The role of preventing the overcharge
Operation
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EV Battery System
Removal
QRA is integrated into the high voltage joint box and so each part cannot be replaced separately. Refer to removal procedure of high
voltage joint box.
Installation
QRA is integrated into the high voltage joint box and so each part cannot be replaced separately. Refer to removal procedure of high
voltage joint box.
EV Battery System
Removal
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[Upper Case]
(Refer to High Voltage Battery System - "High Voltage Battery Pack Assembly")
2. Loosen the safety plug cable assembly bracket mounting bolt (A).
3. After loosening the mounting bolt, remove the battery pack upper case (A).
High voltage battery pack upper case mounting bolt/nut :7.8 ~ 11.8 N.m (0.8 ~ 1.2 kgf.m, 5.8 ~ 8.7 lb-ft)
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[Lower Case]
1. Disassemble the high voltage battery system assembly.
(Refer to High Voltage Battery System - Repair procedrues - "Disassembly")
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Installation
1. Install the case in the reverse order of removal.
EV Battery System
Components Location
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1. BMS ECU 8. Battery Temperature Sensor
2. Main Relay 9. Runaway Arresting Device (RAD)
3. Pre Charge Relay 10. High Voltage Battery Heater (With heater system)
4. Pre Charge Resistor 11. High Voltage Battery Heater Relay (With heater system)
5. Battery Current Sensor 12. High Voltage Battery Heater Fuse (With heater system)
6. Safety Plug 13. High Voltage Battery Heater Temperature Sensor (With heater
7. Main Fuse system)
1. BMS ECU 2. Main Relay

3. Pre Charge Relay
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4. Pre Charge Resistor 6. Safety Plug

5. Battery Current Sensor
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7. Main Fuse 8. Battery Temperature Sensor
9. Runaway Arresting Device (RAD) 10. High Voltage Battery Heater Temperature Sensor
11. High Voltage Battery Heater Fuse

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Power Relay Assembly (Without heater system)
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1. Main Relay (+) 4. Pre Charge Resistor

2. Main Relay (-) 5. Battery Current Sensor
3. Pre Charge Relay
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Power Relay Assembly (With heater system)
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1. Main Relay (+) 5. Battery Current Sensor
2. Main Relay (-) 6. High Voltage Battery Heater Relay
3. Pre Charge Relay 7. High Voltage Battery Heater Fuse
4. Pre Charge Resistor
EV Battery System
Description
High voltage battery control system consists of BMS ECU, PRA and it controls SOC (State of charge), output, trouble shooting, battery cell
balancing, cooling, power supply & disconnect.
Power Relay Assembly (PRA) consists of main relay, precharge relay, precharge resister, battery current sensor and battery heater relay. It is
connected to battery pack through busbar.
[Main Function]
Purpose
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SOC control • Calculation of SOC by measuring the voltage/current/temperature

Battery ouput control • Battery protection, Prediction of available power, Prevention of overcharge/overdischarge by
calculating the input/output energy as the system status
PRA control • Cut off the power to the high voltage system when IG ON/OFF
• Prevent the safety accidents due to high voltage system failure
Cooling control • Maintain the battery temperature by controlling the cooling fan
Trouble shooting • System troubleshooting, data monitoring and software management
(Refer to "Trouble shooting") • Limit the output by Fail-Safe
• Prevent the safety accidents by controlling the relay
• SOC (State Of Charge): Available energy in the battery

• SOC = [Dischargeable current] / [Battery rated capacity] × 100%
High Voltage Battery Heater System

If the temperature is too low, the battery can be frozen and it can cause reduction in the output voltage. So to prevent this, the heater system
for high voltage battery is adopted. It is controlled automatically by the temperature.
The heater relay is controlled by the BMS ECU and when the heater relay is ON, high voltage is supplied to each heater.
Even when the ignition switch is OFF, the VCU operates the BMS ECU regularly to prevent freezing of the battery.
If the temperature reaches normal range, BMS ECU waits until the VCU gives the order to operate the battery heater via CAN communication.
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If the battery SOC is too low while the heater is operating, the BMS ECU stops the heater operation.
If the battery SOC is too low, the heater system will not operate even when the temperature is low.
Operation
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1.Measure the cell voltage, temperature, current and resistance value.
2.Transfer the BMS control data to VCU or control the driving part.
High Voltage Battery Heater System
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EV Battery System
Circuit Diagram
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High Voltage Circuit Diagram
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EV Battery System
Inspection
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Insulation Resistance Loss Inspection
(Refer to Battery Contorl System - "High Voltage Shut-off Procedure")
2. Remove the high votlage battery upper case.
3. Remove the high voltage power cable (A).
High voltage power cable mounting nut :7.8 ~ 11.8 N.m (0.8 ~ 1.2 kgf.m, 5.8 ~ 8.7 lb-ft)
4. Measure the voltage between the high voltage power cable and the ground cable.
Specified value :Approx. 0 V
EV Battery System
Specification
C-CAN terminating resistance (Ω) Approx. 60 Combined resistance (BMS ECU↔Inverter)
C-CAN terminating resistnace (Ω) Approx. 120 BMS ECU resistance
EV Battery System

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Connector Location
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BMS ECU Connector And Terminal Function
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BMS ECU Terminal Function
A Connector [B01-A] (35 Pin) - Voltage Measurement Connector
Pin no. Description Connected to
1 Battery Cell [Module 8/Cell 13] Voltage Input Battery Cell [Module 8/Cell 13]
6 Battery Cell [Module 7/Cell 1] Voltage Input Battery Cell [Module 7/ Cell 1]
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15 Battery Cell [Module 8/the Lower Line Cell] Voltage Input Battery Cell [Module 8]
19 Battery Cell [Module 7/Cell 5] Voltage Input Battery Cell [Module 7/Cell5]
21 Battery Cell [Module 7/the Lower Line Cell] Voltage Input Battery Cell [Module 7]
24 -
32 Battery Cell [Module 7/Cell 5] Voltage Input Battery Cell [Module 7]
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B Connector [B01-B] (26 Pin) - Voltage Measurement Connector

2 Battery Cell [Module 6/Cell the Lower Line] Voltage Input Battery Cell [Module 6]
3 -
9 -
14 -
24 -
C Connector [B01-C] (28 Pin) - Voltage Measurement Connector

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14 Battery Cell [Module 4/ the Lower Line Cell] Voltage Input Battery Cell [Module 4]
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D Connector [B01-D] (30 Pin) - Voltage Measurement Connector

4 Battery Cell [Module 2/ the Lower Line Cell] Voltage Input Battery Cell [Module 2]
7 -
23 -
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E Connector [B01-E] (26 Pin) - Control Connector

1 Quick Charge Main Relay [+] Control High Voltage Joint Box
2 High Voltage Main Relay [-] Control Power Relay Assembly (PRA)
3 High Voltage Main Relay [+] Control Power Relay Assembly (PRA)
4 Pre Charge Relay Control Power Relay Assembly (PRA)
5 High Voltage Cooling Fan Relay Control (FCTC) High Voltage Cooling Fan Relay Control
6 Cooling Pan Speed Control High Voltage Battery Cooling Pan
7 Cooling Pan Feedback Input Signal High Voltage Battery Cooling Pan
8 Quick Charge SS2 Input Signal Quick Charge Port
9 -
10 Quick Charge PD Input Signal Quick Charge Port
11 High Voltage Joint Box Interlock Input Signal High Voltage Joint Box
12 Battery Current Sensor Input Signal Power Relay Assembly (PRA)
13 Battery Current Sensor Power (+5V) Power Relay Assembly (PRA)
14 Quick Charge Main Relay (-) Control High Voltage Joint Box
15 Quick Charge Main Relay Ground High Voltage Joint Box
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16 High Voltage Main Relay Ground Power Relay Assembly (PRA)
17 High Voltage Battery Heater Relay Control Power Relay Assembly (PRA)
18 -
19 -
20 -
21 Collision Test Input Signal (Crash) Collision detection signal
22 -
23 -
24 -
25 -
26 Battery Current Sensor Ground Power Relay Assembly (PRA)
F Connector [B01-F] (16 Pin) - Temperature Measurement Connector

1 Battery Temperature Sensor #4 [Module4] Signal Input Battery Temperature Sensor #4
5 -
6 High Voltage Battery Heater Temperature Sensor #1 [Module1] High Voltage Battery Heater Temperature Sensor #1
Signal Input
7 -
8 Safety Plug Interlock Signal Input Interlock (Included in the Safety Plug)
9 Battery Temperature Sensor #4 [Module4] Ground Battery Temperature Sensor #4
13 -
14 High Voltage Battery Heater Temperature Sensor #1 [Module1] HighVoltage Battery Heater Temperature Sensor #1
Ground
15 -
16 Safety Plug Interlock Ground Interlock (Included in the Safety Plug)
G Connector [B01-G] (12 Pin) - Temperature Measurement Connector

1 Battery Temperature Sensor #8 [Module 8] Signal Input Battery Temperature Sensor #8
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5 Inlet Temperature Sensor Signal Input Inlet Temperature Sensor
6 High Voltage Battery Heater Temperature Sensor #2 [Module2] HighVoltage Battery Heater Temperature Sensor #2
Signal Input
7 Battery Temperature Sensor #8 [Module 8] Ground Battery Temperature Sensor #8
11 Inlet Temperature Sensor Ground Inlet Temperature Sensor
12 High Voltage Battery Heater Temperature Sensor #2 [Module2] High Voltage Battery Heater Temperature Sensor #2
Ground
H Connector [B01-H] (22 Pin) - Control Connector

1 Inverter Interlock Signal Input Power Relay Assembly (PRA)
2 Other Control Module, Data Link Connector (DLC), Multi-Check
C-CAN [Low]
Connector
3 Other Control Module, Data Link Connector (DLC), Multi-Purpose
C-CAN [High]
Check Connector
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CCP-CAN [Low]
Check Connector
CCP-CAN [High]
Check Connector
6 -
7 Runaway Arresting Device (RAD) Signal Input Runaway Arresting Device (RAD)
8 Normal charging device ON (Wake up) Signal Input Normal charging device, IG3 #2 Relay
9 IG3 Power 12V Auxiliary Battery
10 Battery Power (B+) 12V Auxiliary Battery, IG3 #1/2/3 Relay
11 Battery Power (B+) 12V Auxiliary Battery, IG3 #1/2/3 Relay
12 -
13 -
14 -
15 -
16 -
17 -
18 Quick Charge Port Signal Input (Pilot) Quick Charge Port
19 -
20 -
21 Power Ground Chassis Ground
22 Power Ground Chassis Ground
BMS ECU Terminal Input/Output Signal

A Connector [B01-A] (35 Pin) - Voltage Measurement Connector
Pin
Description Condition Type Level Wave Remark
no.
Battery Cell [Module 8/Cell 13]

1 IG Off DC Voltage 1.5 ~ 4.8V No.8 Module No.13 Cell
Voltage Input

Voltage Input

Voltage Input
4 Battery Cell [Module 8/Cell 4] IG Off DC Voltage 1.5 ~ 4.8V No.8 Module No.4 Cell
Voltage Input
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Voltage Input

Voltage Input

Voltage Input

Voltage Input

Voltage Input

Voltage Input
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Voltage Input

Voltage Input

Voltage Input

Voltage Input
Battery Cell [Module 8/Cell The No.8 Module The Lower

15 IG Off DC Voltage 1.5 ~ 4.8V
Lower Line] Voltage Input Line

Voltage Input

Voltage Input

Input

Voltage Input

Voltage Input


Voltage Input

Voltage Input
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24 -

Voltage Input

Voltage Input

Voltage Input

Voltage Input

Voltage Input

Voltage Input

Voltage Input
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Voltage Input

Voltage Input

Voltage Input

Voltage Input
B Connector [B01-B] (26 Pin) - Voltage Measurement Connector

Pin
no.

Voltage Input

3 -

Voltage Input

Voltage Input


Voltage Input
Voltage Input
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9 -

Voltage Input

Voltage Input

Voltage Input

Voltage Input
14 -

Voltage Input

Voltage Input

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Voltage Input

Voltage Input

Voltage Input

Voltage Input

Voltage Input

Voltage Input

Voltage Input
24 -

Voltage Input

Voltage Input
C Connector [B01-C] (28 Pin) - Voltage Measurement Connector

Pin
no.

Voltage Input

Voltage Input
Voltage Input
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Voltage Input

Voltage Input

Voltage Input


Voltage Input

Voltage Input
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Voltage Input

Voltage Input

Voltage Input

Voltage Input
Battery Cell [Module 4/Cell The No.4 Module Cell The

Lower Line] Voltage Input Lower Line

Voltage Input

Voltage Input

Voltage Input

Voltage Input

Voltage Input

Voltage Input

Voltage Input

Voltage Input
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Voltage Input

Voltage Input

Voltage Input

Voltage Input

Voltage Input

Voltage Input
D Connector [B01-D] (30 Pin) - Voltage Measurement Connector

Pin
no.
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1 IG Off DC Voltage 1.5 ~ 4.8V 2 Module No.8 Cell
Voltage Input

Voltage Input

Voltage Input


Voltage Input

Voltage Input
7 -

Voltage Input

Voltage Input

Voltage Input

Voltage Input

Voltage Input

Voltage Input

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Voltage Input

Voltage Input

Voltage Input

Voltage Input

Voltage Input

Voltage Input

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Voltage Input

Voltage Input
23 -

Voltage Input

Voltage Input

Voltage Input

Voltage Input

Voltage Input

Voltage Input

Voltage Input
E Connector [B01-E] (26 Pin) - Control Connector

Pin
no.
On : VB ± 1.0V Quick Charger Main

Quick Charge Main Relay [+] QuickCharger DC
1 Relay Control Signal
Control Connect Voltage Off : Max 1.0V
(Active High)
High Voltage Main Relay [-] DC On : VB ± 1.0V Main Relay Control

2 Starting
Control Voltage Off : Max1.0V Signal (Active High)
3 Starting
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High Voltage Main Relay [+] DC On : VB ± 1.0V Main Relay Control

Control Voltage Off : Max1.0V Signal (Active High)
On : VB ± 1.0V Pre Charge Relay

DC
4 Pre Charge Relay Control Starting Control Signal (Active
Voltage Off : Max1.0V
High)
High Voltage Battery Cooling DC On : Max1.0V Cooling Relay Control

5 IG On
Fan Relay Control (FCTL) Voltage Off : VB ± 0.5V Signal (Active Low)
Cooling Pan Speed Control
Cooling fan motor

6 Starting Pulse 0 ~ 5.0V Speed Control Signal
(PWM duty)
Cooling fan Speed

Cooling Pan Feedback Signal Feedback Signal
7 Starting Pulse 0 ~ 5.0V
Input (VF1)
(0 ~ 3000Hz)
Quick Quick Charger and

Quick Charge SS2 Signal DC On : 12 ± 1.0V Off :
8 Charger BMS Interface (SAE
Input Voltage 0.9 V Max
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Connect J1772)
9 -
Quick QuickCharger and
DC On : 0.9V Max Off :
10 Quick Charge PD Signal Input Charger BMS Interface (SAE
Voltage 5.0 ± 0.1V Max
Connect J1772)
Safety Plug
Installation : 0.9V
Max Joint Box in
High Voltage Joint Box DC
11 IG On HighVoltage Connector
Interlock Signal Input Voltage Safety Plug Interlock (Active Low)
Removal : 5.0 ±
0.1V
0A :
Battery Current Sensor Signal DC 2.4 ~ 2.6 V Current Sensor
12 IG On
Input Voltage -300~300A : (Current sensing value)
0.4~4.6V
On :
Battery Current Sensor Power DC 4.9 ~ 5.1 V Current Sensor (Input
13 IG On
(+5V) Voltage Off : Power (5V))
Max1.0V
On :
Quick Quick Charge Main
Quick Charge Main Relay (-) DC VB ± 0.5V
14 Charger Relay Control Signal
Control Voltage Off :
Connect (Active High)
1.0V Max
Quick Max.150mV @
Quick Charge Main Relay DC Quick Charge Relay
15 Charger 12V assistance
Ground Voltage Ground
Connect Battery Ground
Max.150mV @
HighVoltage Main Relay DC Quick Charge Relay
16 IG On 12V assistance
Battery Ground
High voltage
High Voltage Battery
HighVoltage Battery Heater battery DC On : VB ± 1.0V
17 Heater Relay Control
Relay Control heater Voltage Off : Max 1.0V
Signal (Active High)
system action
18 -
19 -
20 -
21 Collision Test Input(Crash) IG On Pulse 0 ~ 5.0V Collision detection
signall (PWM Duty)
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22 -
23 -
24 -
25 -
Max.150mV @
Battery Current Sensor DC Battery Current Sensor
26 IG On 12V assistance
Battery Ground
F Connector [B01-F] (16 Pin) - Temperature Measurement Connector

Pin
no.
Battery Temperature Sensor #4 Battery Temperature

1 IG On DC Voltage 0.3 ~ 4.9V
[Module4] Signal Input Sensor (No.4 Module)

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[Module2] Signal Input Sensor (2번 Module)

5 -
High Voltage Battery Heater High Voltage Battery
6 Temperature Sensor #1 IG On DC Voltage 0.3 ~ 4.9V Heater Temperature
7 -
Safety Plug
Installation : Max
Safety Plug Interlock Signal 0.1V Safety Plug Interlock
8 IG On DC Voltage
Input (Active Low)
Safety Plug
Removal : 4.9 ~ 5.1V

9 IG On DC Voltage 0.1V Max
[Module4] Ground Sensor (No.4 Module)



13 -
High Voltage Battery Heater High Voltage Battery
14 Temperature Sensor #1 IG On DC Voltage 0.1V Max Heater Temperature
15 -
16 Safety Plug Interlock Ground IG On DC Voltage 0.1V Max Safety Plug Interlock
G Connector [B01-G] (12 Pin) - Temperature Measurement Connector

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Pin
no.




Inlet Temperature Sensor Signal

5 IG On DC Voltage 0.3 ~ 4.9V Inlet Temperature Sensor
Input
High Voltage Battery Heater HighVoltage Battery

6 Temperature Sensor #2 IG On DC Voltage 0.3 ~ 4.9V Heater Temperature
Battery Temperature Sensor #8 BatteryTemperatureSensor

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[Module8] Ground Ground



Inlet Temperature Sensor BatteryTemperatureSensor

Ground Ground
High Voltage Battery Heater HighVoltage Battery

12 Temperature Sensor #2 IG On DC Voltage 0.1V Max Heater Temperature
[Module2] Ground Sensor Ground
H Connector [B01-H] (22 Pin) - Control Connector

Pin
no.
Safety Plug
Installation: Max
DC 0.9V Safety Plug Interlock
1 Inverter Interlock Signal Input IG On
Voltage Safety Plug (Active Low)
Removal: 4.9 ~ 5.1
V
Receive :
2.0 ~3.0(2.5)V Vechicle CAN
2 C-CAN [Low] IG On Pulse
Dominant : Communication (Low)
0.5~2.25(1.5)V
Dominant :
2.75~4.5(3.5)V Vechicle CAN
3 C-CAN [High] IG On Pulse
Receive : 2.0~3.0 Communication (High)
(2.5)V
4 CCP-CAN [Low] IG On Pulse

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Receive : Quick Charge CAN

2.0 ~3.0(2.5)V Communication (Low)
Dominant :
0.5~2.25(1.5)V
Dominant :
2.75~4.5(3.5)V Quick Charge CAN
5 CCP-CAN [High] IG On Pulse
Receive : 2.0~3.0 Communication (High)
(2.5)V
6 -
No Operation:
Max1.0V Relay operation
Runaway Arresting Device DC
7 IG On Feedback Signal
(RAD) Signal Input Voltage Operation:
(Active High)
VB ± 1.0V
Quick Quick Charger
Quick Charger ON (Wake up) DC On : 12 ± 1.0V Off :
8 Charger from BMS ECU wake-
Signal Input Voltage 0.9 V Max
connection up Signal
DC
9 IG3 Power IG On 9 < VIG1 < 16V IG3 Signal
Voltage
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DC BMS ECU
10 Battery Power (B+) Always 9 < VB < 16V
Voltage Power
DC BMS ECU
11 Battery Power (B+) Always 9 < VB < 16V
Voltage Power
12 -
13 -
14 -
15 -
16 -
17 -
Quick 0 ~ 12V Quick Charger and
Rapid Charge Port signal DC
18 Charger BMS ECU interface
input (Pilot) Voltage Connect quick
connection Charger 9V or 0V) (SAE J1772)
Safety Plug
Installation: 0.9V
DC Max Safety Plug Interlock
19 Inverter Interlock Signal Input IG On
Voltage Safety Plug (Active Low)
Removal:4.9 ~ 5.1
V
20 -
DC Max.150mV @12V
21 PowerGround Always Ground
Voltage Battery Ground
DC Max.150mV @12V
22 PowerGround Always Ground
Voltage Battery Ground
EV Battery System
Inspection
C-CAN Terminating Resistance Inspection (Multi Purpose Check Connector)
2. Measure the resistance between pins No. 20 and No. 17 of multi purpose check connector (20 pins).
Measure the resistance between pins No. 3 and No. 11 of DLC (16 pins).
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Specified value :Approx. 60 Ω
3. If the measured vaule is not whithin the specification, check the terminating resistance between the BMS ECU and the Inverter.
C-CAN Terminating Resistance (BMS ECU)
1. Turn the ignition OFF and disconnect the auxiliary battery negative (-) terminal.
3. After loosening the mounting nut, remove the high voltage battery front under cover (A).
4. Disconnect the BMS ECU extension connector (A).

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5. Measure the resistance between pins No. 2 (CAN-High) and No. 9 (CAN-Low) of BMS ECU.
Specified value :Approx. 120 Ω
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Removal
(Refer to EV Battery System - "High Voltage Shut-off Procedure")
(High Voltage Battery System - Battery Pack Assembly - "Removal")
High voltage battery pack upper case mounting bolt:7.8 ~ 11.8 N.m (0.8 ~ 1.2 kgf.m, 5.8 ~ 8.7 lb-ft)
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5. Remove the BMS ECU

(1) Disconnect the connector (A).
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(2) Remove the mounting nut (B).
(3) Remove the BMS ECU(C).
BMS ECU mounting nut:7.8 ~ 11.8 N.m (0.8 ~ 1.2 kgf.m, 5.8 ~ 8.7 lb-ft)
Installation
1. Install the BMS ECU in the reverse order of removal.
EV Battery System
Specification
Item Specification
ON Rated Ampere (A) 200
Coil
Resistance (Ω) 21.6 ~ 26.4 (20°C)
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Main Relay Fixing Status NO Checkable by GDS
Main Relay Operation Beep "Clicking" Checkable by GDS and SST
Coil Resistance (Ω) 21.6 ~ 26.4 (20°C) Checkable by multi tester
EV Battery System
Description
Main Relay is installed in the Power Relay Assembly (PRA) and it controls the high voltage line.
It connects the power between the high voltage battery pack and the high voltage joint box by the BMS ECU control signal.
But when the battery cell is swollen by overcharging, main relay and pre charge relay (PRA) are not operated by RAD.
The RAD is installed on each battery module and will not operate when the battery is normal.
[With High Voltage Battey Heater System]
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1. Main Relay (+)

2. Main Relay (-)
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3. Pre Charge Relay 5. Battery Current Sensor

4. Pre Charge Resistor 6. High Voltage Battery Heater Relay
7. High Voltage Battery Heater Fuse
[Without High Voltage Battery Heater System]
1. Main Relay (+)

2. Main Relay (-)
3. Pre Charge Relay
5. Battery Current Sensor cardiagn.com
Operation
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EV Battery System

With High Voltage Battery Heater System
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Without High Voltage Battery Heater System
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Circuit Diagram
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EV Battery System
Inspection
Main Relay (-) Inscpection
[Using multi tester (Relay OFF)]
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Inspect the high voltage main relay (-) by using multi tester when the relay is off
3. Measure the resistance between the high voltage (-) power terminal and the Inverter (-) terminal.
[Using GDS (Relay ON)]

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3. Connect the SST No: 0K918-E4100, 0K375-E4100, 0K375-E4200 to the vehicle.

6. Activate the main relay (-) by using "Actuation Test" on the GDS as shown in the illustration below.
When the relay is ON, there is a relay operation sound.

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Main Relay Coil Resistance

(Refer to High Voltage Battery System - "Power Relay Assembly (PRA)")
3. Measure the resistance of the main relay (+) (between the No.6 and the No.10) and the main relay (-) (between the No.4 and the No.6).
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Specification :21.6 ~ 26.4 Ω (20°C)
Removal
Main Relay, Pre Charge Relay, Pre Charge Resistor, Battery Current Sensor, High Voltage Battery Heater Relay and the High Voltage
Battery Heater Fuse are integrated in the Power Relay Assembly (PRA). So Refer to the removal procedure of Power Relay Assembly
(PRA).
Installation
Battery Heater Fuse are integrated in the Power Relay Assembly (PRA). So Refer to the installation procedure of Power Relay Assembly
(PRA).
EV Battery System
Specification
Item Specification
Rated Voltage(V) 450
ON Rated Ampere(A) 10
Voltage Drop(V) Less than 0.5 (10A)
Operation Voltage(V) 12
Coil
Resistance(Ω) 104.4 ~ 127.6 (20°C)

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Pre Charger Relay Operation Sound "Clicking" Checkable by GDS and SST
Pre Charger Relay Coil Resistance (Ω) 104.4 ~ 127.6 (20°C) Checkable by multi tester
EV Battery System
Description
Installed in the Power Relay Assembly (PRA), the Pre-charge Relay connects high voltage circuit when pre-charging the inverter capacitor.
When the IG is ON, the current coming through the pre-charge relay and the resistor charges the capacitor in the inverter and when the
capacitor is fully charged, the pre-charge relay turns OFF.
[With High Voltage Battery Heater System]
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3. Pre Charge Relay
Operation
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EV Battery System

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Circuit Diagram
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EV Battery System
Inspection
Pre Charge Relay Inspection
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Inspect the high voltage pre-charge relay by using multi tester when the relay is off
3. Measure the resistance between the high voltage (+) power terminal and the joint box (+) terminal.

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3. Connect the SST(0K918-E4100, 0K375-E4100, 0K375-E4200) to the vehicle.

5. Turn the ignition swtich ON.
6. Activate the pre charge relay by using "Actuation Test" on the GDS as shown in the illustration below.

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Pre Charge Relay Coil Resistance

2. Remove the power relay assembly (PRA)
3. Measure the resistance between pins No. 6 and No. 8 of the power relay assembly connector.
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Specification :104.4 ~ 127.6 Ω (20°C)
Removal
(PRA).
Installation
(PRA).
EV Battery System
Spectification
Item Specification
Capacity (W) 60
Coil
Resistance (Ω) 30
EV Battery System
Description
Pre-Charge Resistor is installed in the Power Relay Assembly (PRA) and it protects the high voltage circuit by limiting the charging current
when the inverter capacitor is being pre-charged.
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3. Pre Charge Relay
Operation
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EV Battery System

With High Votlage Battery Heater System
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Circuit Diagram
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EV Battery System
Removal
(PRA).
Installation
(PRA).
EV Battery System
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Specifications
Current (A) Ouput Voltage (V)
-400(Charge) 0.5
-200 (Charge) 1.5
0 2.5
200 (Discharge) 3.5
Item Specifications Remark

Current Sensor Output Voltage (V) Approx. 2.5 ± 0.1 Checkable by multi tester
Current Sensor Power Voltage (V) Approx. 5 ± 0.1 Checkable by multi tester
EV Battery System
Description
Battery Current Sensor is installed in the Power Relay Assembly and it measures the current when the high voltage battery is being charged
or discharged.
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3. Pre Charge Relay
EV Battery System
Systerm Circuit Diagram

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Circuit Diagram
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EV Battery System
Inspection
(Refer to Battery Control System - "High Voltage Shut-off Prcedure")
4. Remove the high voltage battery pack upper case.
5. Connect the SST (No: 0K918-E4100, 0K375-E4100, 0K375-E4200) to the vehicle as shown in the image below.
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8. Check the "Battery Pack Current" in the GDS service data.
9. Check voltage for each current.

Current (A) Output Voltage (V)
-400(Charge) 0.5
-200 (Charge) 1.5
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0 2.5
200 (Discharge) 3.5
10. Measure the voltage between pins No. 12 (Sensor output) and No. 26 (Sensor ground) of BMS ECU E connector.
Specification :About 2.5V ± 0.1V
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11. Measure the voltage between pins No. 1 (Sensor power) and No. 26 (Sensor ground) of BMS ECU E connector.
Specification :Approx. 5V ± 0.1V
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Removal
(PRA).
Installation
(PRA).
EV Battery System
Description
Safety Plug is installed on the bottom of the rear seat. High voltage circuit can be shut off by removing the safety plug.
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EV Battery System
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Circuit Diagram
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EV Battery System
Inspection
1. Remove the safety plug. (Refer to "Removal")
2. Check the safety plug by visual check and electrical test.
- Check the interlock switch and terminal
Removal
[Safety Plug]
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1. Turn the ignition swtich OFF and disconnect the auxiliary battery negative (-) terminal.
2. Remove the cover (A) on the floor carpet of the rear seat.
3. After loosening the nut, remove the safety plug service cover (A).
Safety plug service cover mounting nut :0.8 ~ 1.2 kgf.m
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4. Remove the safety plug (A).
Remove the safety plug in the following order.
[Safety Plug Cable]

1. Turn the ignition switch OFF and disconnect the auxiliary batter negative (-) terminal.
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3. Remove the high voltage upper case.
4. Disconnect the safety plug cable inerlock connector (A).
5. After loosening the nunt (A), remove the safety plug cable assembly (B).
Safety plug cable assembly mounting nut :0.8 ~ 1.2 kgf.m
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Installation
1. Install the safety plug in the reverse order of removal.
EV Battery System
Specification
Item Specification
Rated Voltage (V) 450 (DC)
Rated Current (A) 250 (DC)

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Safety Plug Cable Resistance (Ω) Less than 1 (20°C) Checkable by multi tester
Main Fuse Resistance (Ω) Less than 1 (20°C) Checkable by multi tester
EV Battery System
Description
Installed in the safety plug, the main fuse protects the high voltage circuit from overcurrent.
EV Battery System
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Circuit Diagram
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EV Battery System
Inspection
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.
Method 2
1. Turn the ignition switch OFF and disconnect the auxiliary battery negative (-) terminal.
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4. Remove the upper fuse box (A).
5. Perform the electrical test of main fuse.

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Removal
Main fuse is combined with the safety plug. Refer to the removal procedure of safety plug.
Installation
Main fuse is combined with the safety plug. Refer to the removal procedure of safety plug.
EV Battery System
Specification
-40 204.5 ±4.0
-30 117.8 ±3.5
- 20 70.34 ±3.0
- 10 43.43 ±2.5
0 27.63 ±2.0
10 18.07 ±1.6
20 12.11 ±1.2
30 8.303 ±1.2
40 5.813 ±1.5
50 4.149 ±1.9
60 3.013 ±2.2
70 2.225 ±2.5
EV Battery System
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Description
Installed in the high voltage battery module, Battery Temperature Sensor transfers temperature of each battery module to BMS ECU.
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EV Battery System
Circuit Diagram
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EV Battery System
Installation
Battery temperature sensor can not be disassembled.

5. Connect the SST (No: 0K918-E4100, 0K375-E4100, 0K375-E4200) as shown in the image below.
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8. Check the "Battery Module Temperature" in the GDS service data.
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9. Turn the ignition swtich OFF.
10. Disconnect the SST (high votlage battery cable & BMS terminal).
11. Check resistance for each temperature sensor.
-40 204.5 ±4.0
-30 117.8 ±3.5
- 20 70.34 ±3.0
- 10 43.43 ±2.5
0 27.63 ±2.0
10 18.07 ±1.6
20 12.11 ±1.2
30 8.303 ±1.2
40 5.813 ±1.5
50 4.149 ±1.9
60 3.013 ±2.2
70 2.225 ±2.5
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EV Battery System
Specification
RAD Combined Resistance (Ω) Less than 3 (20°C) Checkable by multi tester
RAD Terminal Resistance (Ω) Less than 0.375 (20°C) Checkable by multi tester
RAD Switch Position Bottom RAD switch and visual inspection
EV Battery System
Components Location
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1. Runaway Arresting Device (RAD) 2. Runaway Arresting Device (RAD) Wiring Harness
EV Battery System
Description
RAD is installed on each battery module.
If the high voltage battery is swollen by cell overcharge, RAD cuts the ground of the main relay and the pre-charge relay.
If the cell is overcharged, the switch turns OFF and the vehicle cannot be driven.
RAD
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RAD on 10 cells
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RAD on 14 cells
RAD Wiring Harness
Operation
Module Normal Failure
Current ON (Connected) OFF (Cut off)
RAD - Switch rise
High Voltage Normal Cut off
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Phenomenon Normal Failure on starting the motor and warning light
Diagram
EV Battery System
Circuit Diagram
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EV Battery System
Inspection
Failure to follow the safety instructions may result in serious electrical injuries
0K375-E4100, 0K375-E4200.
1. Turn the ignition switch OFF and disconnect the auxiliary batter negative (-) terminal.
(Refer to Battery Control System - "High Voltage Shut-off Prcedure")
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(Refer to High Votlage Battery System - "Case")
4. Measure the combined resistance of RAD terminal.
Specification :Less than 3 Ω (20°C)
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5. Measure the resistance of each RAD.
Specification :Less than 0.375Ω (20°C)
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[If not correct]
1. Check that the RAD switch is facing down.
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2. Be careful not to reverse the battery No. 1 module RAD connector (2 pins) and the BMS extension connector (1 pin).
3. Be careful not to reverse the battery No. 8 module RAD connector (2 pins) and the BMS extension connector (1 pin).
EV Battery System
Specification
[14 cells LH/ RH]
Item Specification
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[10 cells LH/ RH]

Item Specification
EV Battery System
Component
1. High Voltage Battery Heater 3. High Voltage Battery Heater Fuse

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2. High Voltage Battery Heater Relay 4. High Voltage Battery Heater Temperature Sensor
EV Battery System
Description
High Voltage Battery Heater is installed in every module and it is controlled by heater relay.
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High Voltage Flow
Control Flow
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Operation
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EV Battery System

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EV Battery System cardiagn.com

Inspection
0K375-E4100, 0K375-E4200.
(Refer to High Voltage Battery System - Repiar procedures - "Removal")
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5. Measure the resistance.
14 cells LH/ RH
Item Specification
10 cells LH/ RH
Item Specification
LH
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RH cell heater
Removal
High Voltage Battery Heater, High Voltage Battery Heater Temperature Sensor and Inlet Temperature Sensor are combined with High
Voltage Battery Pack Assembly. Refer to the removal procedure of high voltage battery pack assembly.
Installation
High Voltage Battery Heater, High Voltage Battery Heater Temperature Sensor and Inlet Temperature Sensor are combined with High
Voltage Battery Pack Assembly. Refer to the removal procedure of high voltage battery pack assembly.
EV Battery System
Specification
Item Specification
ON Rated Current (A) 10
Coil
Resistance (Ω) 104.4 ~ 127.6 (20°C)
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Heater Relay Switch Resistance (Ω) ∞ Checkable by multi tester
Heater Relay Operation Sound "Clicking" Checkable by GDS and SST
Heater Relay Coil Resistance (Ω) 104.4 ~ 127.6 (20°C) Checkable by multi tester
EV Battery System
Component
1. Battery Heater 3. Battery Heater Fuse

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2. Battery Heater Relay 4. Battery Heater Temperature Sensor
EV Battery System
Description
High Voltage Battery Heater Relay is installed in the Power Relay Assembly (PRA).
It supplies high voltage flow inside the heater to operate the heater to warm the high voltage battery.
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Control Flow
Operation
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EV Battery System

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Circuit Diagram
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EV Battery System
Inspection
0K375-E4100, 0K375-E4200.
High Voltage Battery Heater Relay Switch Resistance
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Inspect the high voltage high voltage battery heater relay by using multi tester when the relay is off
3. Measure the resistance between the heater relay (+) switch terminal and the (+) power terminal which is connected to high voltage joint
box.

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3. Connect the SST(0K918-E4100, 0K375-E4100, 0K375-E4200) to the vehicle.

5. Turn the ignition swtich ON.
6. Activate the battery heater relay by using "Actuation Test" on the GDS as shown in the illustration below.

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High Voltage Battery Heater Relay Coil Resistance

3. Measure the resistance between the No.6 and No.7 of power relay assembly connector.
Specification :104.4 ~ 127.6 Ω
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Removal
(PRA).
Installation
(PRA).
EV Battery System
Specification
Item Specification
Current (A) 10
EV Battery System
Component
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EV Battery System
High Voltage Battery Heater Fuse

It is connected to battery heater relay switch and it cuts off the circuit in case of overcurrent.
It is installed in the Power Relay Assembly (PRA).
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Operation
EV Battery System cardiagn.com

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Circuit Diagram
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EV Battery System
Removal
(PRA).
Installation
(PRA).
EV Battery System
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Specification
Temperature (°C) Resistance (kΩ) Tolerance (%)
-40 204.5 ±4.0
-30 117.8 ±3.5
- 20 70.34 ±3.0
- 10 43.43 ±2.5
0 27.63 ±2.0
10 18.07 ±1.6
20 12.11 ±1.2
30 8.303 ±1.2
40 5.813 ±1.5
50 4.149 ±1.9
60 3.013 ±2.2
70 2.225 ±2.5
EV Battery System
Component
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EV Battery System
Description
It senses the temperature to determine if the battery heater is operating well according to conditions.
EV Battery System
Circuit Diagram
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EV Battery System
Inspection
High voltage battery heater temperature sensor is installed in modules No. 1 and No. 8.
5. Connect the SST (No: 0K918-E4100, 0K375-E4100, 0K375-E4200) as shown in the image beow.
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8. Check the "Heater Temperature" in the GDS service data.

10. Disconnect the SST (High voltage battery cable & BMS terminal).
11. Check resistance for each temperature.
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-40 204.5 ±4.0

-30 117.8 ±3.5
- 20 70.34 ±3.0
- 10 43.43 ±2.5
0 27.63 ±2.0
10 18.07 ±1.6
20 12.11 ±1.2
30 8.303 ±1.2
40 5.813 ±1.5
50 4.149 ±1.9
60 3.013 ±2.2
70 2.225 ±2.5
Removal
(PRA).
Installation
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(PRA).
EV Battery System
Component
High Voltage Battery
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1. Cooling Fan 4. Battery Module Outlet Duct

2. Outlet Cooling Duct 5. Inlet Temperature Sensor
3. Protector Outlet Duct Panel
Vehicle
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1. Cooling Fan Relay
EV Battery System
Description
The system temperature is calculated by the BMS based on 8 temperature sensor signals. And the cooling fan is conrolled in 9 steps to
maintain the normal temperature of high voltage battery system.
The air-cooling method is applied in the cooling system where indoor air is used to cool down the high voltage battery pack assembly.
Operation
Control Flow
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Air Flow
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1. Cooling fan operates.
2. Indoor air flows into the cooling duct (inlet).
3. Cools down the high voltage battery in the direction of the arrows.
4. Air is ventilated out through the cooling duct (outlet).
EV Battery System
Specification
Cooling Fan Speed Duty (%) Fan Speed(rpm)
0 0 0
1 10 900
2 20 1200
3 30 1500
4 40 1800
5 50 2100
6 60 2450
7 70 2600
8 80 2800
9 90 3000
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EV Battery System
Description
It controls the BLDC motor speed by the PWM signal of BMS ECU.
EV Battery System
Inspection
1. Turn the ignition switch OFF and disconnect the auxiliary battery (12V) negative (-) terminal.
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4. Inspect "Control Duty" and waveforms according to "Fan Status" by performing "Actuation Test" on GDS.
Cooling Fan Speed Duty (%) Fan Speed (rpm)
0 0 0
1 10 900
2 20 1200
3 30 1500
4 40 1800
5 50 2100
6 60 2450
7 70 2600
8 80 2800
9 90 3000
[Cooling Fan at 1st Speed]

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[Cooling Fan at 2nd Speed]
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[Cooling Fan at 3rd Speed]
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[Cooling Fan at 4th Speed]
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[Cooling Fan Stop]
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Removal
1. Turn the ignition switch OFF and disconnect the auxiliary (12V) negative (-) terminal.
2. Remove the rear cushion.
(Refer to Body - "Rear Seat Assembly")
3. After loosening the nut (A), remove the protector outlet duct panel (B).
Protector outlet duct panel mounting nut :7.8 ~ 11.8 N.m (0.8 ~ 1.2 kgf.m, 5.8 ~ 8.7 lb-ft)
4. Open the trunk.

5. Remove the luggage board (A).
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6. After loosening the bolt (A), remove the outlet cooling duct (B).
Outlet cooling duct mounting bolt :7.8 ~ 11.8 N.m (0.8 ~ 1.2 kgf.m, 5.8 ~ 8.7 lb-ft)
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7. After loosening the nut (A), remove the cooling fan (B).
Cooling fan mounting nut :7.8 ~ 11.8 N.m (0.8 ~ 1.2 kgf.m, 5.8 ~ 8.7 lb-ft)
Installation
1. Install in the reverse ordrer of removal.
EV Battery System
Description
It works as the air flow path when cooling fan operates.
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Protector Outlet Duct Panel
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Outlet Cooling Duct
EV Battery System
Removal
(Refer to High Votlage Battery System - Case - "Upper Case")
2. After loosening the nut, remove the battery module outlet duct (A).
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Protector Outlet Duct Panel
1. Turn the ignition switch OFF and disconnect the auxiliary battery (12V) negative (-) terminal.
2. Remove the rear seat cushion.
(Refer to Body - "Rear Seat Assembly")
3. After loosening the nut (A), remove the protector outlet duct panel (B).
Outlet Cooling Duct

1. Turn the igntion swtich OFF and disconnect the auxiliary battery (12V) negative (-) termianl.
2. Remove the rear seat cushion.
(Refer to Body - Rear Seat Assembly")
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3. After loosening the nut (A), remove the protector outlet duct panetl (B).
4. Open the trunk.

5. Remove the luggage board (A).
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6. After loosening the bolt (A), remove the outlet cooling duct (B).
Outlet cooling duct mounting bolt :7.8 ~ 11.8 N.m (0.8 ~ 1.2 kgf.m, 5.8 ~ 8.7 lb-ft)
Installation
1. Install in the reverse order of removal.
EV Battery System
Specification
-40 204.5 ±4.0
-30 117.8 ±3.5
- 20 70.34 ±3.0
- 10 43.43 ±2.5
0 27.63 ±2.0
10 18.07 ±1.6
20 12.11 ±1.2
30 8.303 ±1.2
40 5.813 ±1.5
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50 4.149 ±1.9
60 3.013 ±2.2
70 2.225 ±2.5
EV Battery System
Description
Inlet temperature sensor is installed on the No.8 module of high voltage battery and it detects the inner air temperature of battery. The
operation of cooling fan depends on the inlet temperature sensor value.
Inlet Temperature Sensor
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Installation (on the No.8 battery module)
EV Battery System
Circuit Diagram
EV Battery System
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Inspection
1. Turn the ignitionswitch OFF.
3. Remove the high voltage battery System assembly.
5. Connect the SST (No: 0K918-E4100, 0K375-E4100, 0K375-E4200) as shown in the image below.
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8. Check the "Battery Inlet Temperature" in the GDS service data.
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10. Disconnect the SST (high votlage battery cable & BMS check cable).
11. Check the resistance by the temperature.
-40 204.5 ±4.0
-30 117.8 ±3.5
- 20 70.34 ±3.0
- 10 43.43 ±2.5
0 27.63 ±2.0
10 18.07 ±1.6
20 12.11 ±1.2
30 8.303 ±1.2
40 5.813 ±1.5
50 4.149 ±1.9
60 3.013 ±2.2
70 2.225 ±2.5
Removal
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High Voltage Battery Heater, High Voltage Battery Heater Temperature Sensor and Inlet Temperature Sensor are integrated into the high
voltage battery pack assembly. So refer to the removal procedure of high voltage battery pack assembly.
Installation
High Voltage Battery Heater, High Voltage Battery Heater Temperature Sensor and Inlet Temperature Sensor are integrated into the high
voltage battery pack assembly. So refer to the removal procedure of high voltage battery pack assembly.
EV Battery System
Components
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1. On-Board Charger (OBC) 3. Normal Charge Port
2. Rapid Charge Port 4. High Voltage Battery
EV Battery System
Description
Electric vehicle can be charged by two methods, rapid charge and normal charge.
In the case of normal charge, the battery is charged after 220V AC power is transformed to DC power by On-Board Charger (OBC). In the
case of rapid charge, the DC power from charging station goes directly to the battery.
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While charging the vehicle, the driving of the vehicle is restricted logically for safety. And the vehicle cannot be charged by two charge
methods at the same time.
The logic is controlled by BMS ECU and IG relays #1,2,3.
IG 3 signal activates the Low Voltage DC-DC Converter (LDC), BMS ECU, Motor Control Unit (MCU), Vehicle Control Unit (VCU) and On-
Board Charger (OBC), and it enables the vehicle to be charged.
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• IG3 Signal: It is the signal only for the Electric Vehicle. The signal goes to Low Voltage DC-DC Converter (LDC), BMS ECU, Motor
Control Unit (MCU), Vehicle Control Unit (VCU) and On-Board Charger.
• IG3 #1 Relay : When the high voltage controller operates, IG3 signal is provided through the IG3 #1 relay, except for normal or rapid
charge,.
• IG3 #2 Relay : In the case of normal charge, it operates to provide the IG3 signal.
• IG3 #3 Relay : In the case of rapid charge, it operates to provide the IG3 signal.
EV Battery System
Specification
Maximum Output 6.6kW
Output Density 0.52kVA/ℓ
Size 327 X 367 X 105 mm
ICCB Approx. 1.4kW
EVSE 6.6kW
EV Battery System
Description
In normal charge, the battery is charged through the On-Board Charger (OBC) using external power supply of 220V.
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On-Board Charger (OBC) is the equipment that charges the high voltage battery of electric vehicle using the 110 ~ 220V AC power. Its
maximum output is 6.6 kW and the efficiency is about 91%.
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Main Function
Item Contents
Control Control the input current power factor To satisfy the AC power standar
• When exceeds the OBC maximum capacity
Limit the maximum output
Protect • When exceeds the OBC limit temperature
Troubleshooting Detect the failure of OBC
Cooperative Cooperative control with other system at pre scheduling
Cooperative control the driving charge / air conditioning
control
EV Battery System
Schematic Diagrams
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Input Connector (AC)
Specification
Terminal Description
Current (normal) Voltage (maximum)
1 Phase voltage (L1)_220VAC
2 Ground 33A 310VAC
3 Phase voltage (L2)_220VAC
Output Connector (DC)

Specification
1 High Voltage Battery (-)
2 High Voltage Battery (+)
25A 495VDC
3 High Voltage Interlock Pin
4 High Voltage Interlock Pin
Signal Connector
Specification
1 Ground 0V
2 IG3 18V
3 Connection sensing (EVSE) 5V
4 Control Pilot (EVSE) 12V
5 Relay operation 18V
6 CAN_Low 1.5-2.5V
1A
7 CAN-High 2.5-3.5V
8 Charge state indication (Right) 18V
9 Charge state indication (Center) 18V
10 Charge state indication (Left) 18V
11 CP, PD Shielding ground 0V
12 Auxiliary 12V battery (+) 18V
EV Battery System
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Removal
Procedure"). Failure to follow the safety instructions may result in serious electrical injuries
2. Remove the high voltage joint box.
(Refer to High Voltage Distribution System - "High Voltage Joint Box")
3. Drain the coolant by loosening the drain plug.
(Refer to Traction Motor System - "Coolant")
4. Disconnect the OBC cable connector (A) and OBC signal connector (B).
5. Loosen the connector bracket mounting bolt (C) and then remove the connector bracket (D) from the OBC.
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6. Disconnect the OBC coolant hose (A).
7. Loosen the mounting bolt and then remove the reservoir tnak (A) from the OBC.
8. Loosen the A/C accumulator mounting bolt (A). (With Heat Pump)
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9. Loosen the OBC mounting bolt (A) and then remove the OBC.
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Installation
1. Install the OBC in the reverse order of removal.
OBC mounting bolt : 1.0 ~1.2kgf.m
When injecting the coolant, perform the air bleeding by activating the EWP using GDS.
(Refer to Motor Cooling System - "Coolant")
EV Battery System
Specification
Output
100kW DC 500V, 200A
50kW DC 450V, 110A
EV Battery System
Description
Rapid charge charges the battery using high voltage on a quick charge stand.
The electric power goes directly to the battery through the rapid charge port. To protect the battery, it is charged up to 84% in the first charge,
and this can be recharged upto 95% in the second charge.
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Quick charge relay and PRA relay safely protect the rapid charge port by cutting the current to rapid charge port. The current flows through
the quick charge relay and the PRA relay only when the connector is connected to rapid charge port.
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EV Battery System
Description
Charge port consists of normal charge port (1) and the rapid charge port (2) in the front of vehicle. The charge starts when the ICCB or the
quick charge coonnector is connected to charge port.
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1. Normal Charge Port

2. Rapid Charge Port
EV Battery System
Removal
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Normal Charge Port

2. Disconnect the auxiliary battery (12V) negative (-)terminal.
3. Remove the front bumper cover.
(Refer to Body - "Front Bumper Cover")
4. Disconnect the wiring harness connector (A) and then remove the normal charge connector (B) from the connector bracket (C).
5. Remove the normal charge wiring fixing clip (D) from the cooling fan shroud.
6. Disconnect the normal charge cable connector (A).
Disconnect the cable in the following order.

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7. Remove the normal charge port (A).

Tightening torque :10.8 ~ 13.7 N.m (1.1 ~ 1.4 kgf.m, 7.9 ~ 10.1 lb-ft)
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Rapid Charge Port
2. Disconnect the auxiliary batter (12V) negative (-) terminal.
3. Remove the front bumper cover.
(Refer to Body - "Front Bumper Cover")
4. Disconnect the wiring harness connector (A) and then remove the normal charge connector (B) from the connector bracket (C).
5. Disconnect the rapid charge cable connector (A).

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Disconnect the cable in the following order.
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6. Remove the rapid charge port (A).
Tightening torque :1.1 ~ 1.4 kgf.m

EV Battery System
Components Location
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1. High voltage joint box 5. PTC heater high voltage cable
2. Air conditioning compressor high voltage connector 6. High voltage battery assembly high voltage cable
3. Electric power control unit (EPCU) high voltage cable 7. High voltage joint box connector
4. On-board charger (OBC) high voltage cable connector 8. Quick charge high voltage cable
EV Battery System
Description
Function: The high voltage joint box distribute high voltage to the each unit of vehicle.
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High-voltage power charge / output system flow
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EV Battery System
Removal
• Do not remove the high voltage joint box cover. You will be killed or hurt.
• Do not disassemble the parts inside.
1. Remove the PE room cover (A).
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2. Disconnect the quick charge high voltage cable (A).
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3. Disconnect the high voltage joint box connector (A).
4. Disconnect the air conditioner compressor high voltage connector (A).
5. Disconnect the high voltage battery cable (A).

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6. Disconnect the PTC heater high voltage connector (A).
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7. Disconnect the EPCU high voltage cable (A).
8. Disconnect the on-board charger high voltage connector (A).
9. Remove the high voltage joint box (A) after loosening bolts.
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Installation
• If a high voltage connector is not connected make sure that the pins are bent.
• Do not insert to strong force a high-voltage connector.
EV Battery System
Components Location
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1. 3-phase high voltage cable [MCU - Motor] 2. High voltage cable [High voltage battery - High voltage joint box]
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EV Battery System
Removal
[High voltage battery pack - High voltage joint box]
• Be sure to shut off the high voltage before doing any work related with the high voltage system (Refer to "High Voltage Shut-off
1. Remove the PE room cover (A).
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2. Disconnect the high voltage battery cable (A).
3. Remove the under cover (A).

4. Remove the high voltage cable together with protector bracket from body of vehicle after loosening protector bracket nuts (A).
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5. Remove the under cover (A) of high voltage battery.

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6. Disconnect the high voltage cable (A) from the high voltage battery.
7. Remove the high voltage cable (A) together with protector bracket from body of vehicle after loosening protector bracket nut.
[MCU - Motor]
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• Be sure to shut off the high voltage before doing any work related with the high voltage system (Refer to "High Voltage Shut-off
1. Remove the under cover (A) of high voltage battery.
2. Remove the motor high voltage cable (A) from the motor and the MCU.
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Installation
• If a high voltage connector is not connected make sure that the pins are bent.
• Do not insert to strong force a high-voltage connector.

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Page 1 sur 245

• All the high voltage wiring and connectors are in orange.

Name Illustration Description

Used when inspecting or working on the high voltage

Used in the following cases :

All removed high voltage components are placed on an

Insulation sheet is used to cover high voltage components to

Personal Protective Equipment Inspection

• Check that the personal protective equipment is not damaged.

Precautions when handling high voltage battery

• Battery Control System - Refer to "High Voltage Battery Handling Guide"

Precautions in case of fire in High Voltage Battery System

Precautions in case of high voltage battery gas and/or electrolyte leakage

Precautions when handling vehicle after an accident

Preparations when servicing accident affected vehicle

Precautions when EV is unattended for a prolonged period

Hybrid Vehicle Refrigerant Recovery / Charging Precautions

High Voltage Shut-off Procedure

Remove the safety plug in the follwing order.

(3) Remove the high voltage cable (A).

High voltage battery system inspection guide

Classification Inspection process Inspection results Measures

3. Measure the high voltage battery/chassis

Main Fuse Inspection

5. Perform the electrical test of main fuse.

Checking for Welding in the High Voltage Main Relay

5. Check for damage on welding in the high voltage main relay.

Insulation Resistance Inspection (With vehicle)

Insulation Resistance Inspection (With battery)

3. Remove the protect cover (A) of power relay assembly (PRA).

Classification Item Measures

Take insulation actions for parts that may short circuit

High Voltage Battery Handling Guide

High Voltage Battery System

Item Specification Note

Item Specification Note

Item Specification Note

Item Specification Remark

Battery Current Sensor

Item Specifications Remark

Item Specification Remark

Battery Temperature Sensor

Runaway Arresting Device (RAD)

High Voltage Battery Heater

[14 Cell LH/ RH]

[10 Cell LH/ RH]

High Voltage Battery Heater Relay

Item Specification Remark

High Voltage Battery Heater Fuse

High Voltage Battery Heater Temperature Sensor

High Voltage Battery Cooling System

Inlet Temperature Sensor

High Voltage Charging System

Item N.m kgf.m lb-ft

High Voltage Battery System

Item N.m kgf.m lb-ft

High Voltage Battery Control System

Item N.m kgf.m lb-ft

High Voltage Battery Cooling System

Item N.m kgf.m lb-ft

High Voltage Charging System

High Voltage Distributing System