Hybrid System - HEV System Service Safety Precautions
NUMBER: 11-GI-006MODEL(S): Sonata Hybrid (YF HEV)
GROUP: General
DATE: April, 2011
SUBJECT
SAFETY WARNINGS BEFORE YF HEV HIGH-VOLTAGE SYSTEM SERVICE
Description:
This bulletin provides the safety precautions that should be taken before repairing SONATA HEV high-voltage components (using DC 270V), such as high-voltage battery pack assembly, power relay assembly (PRA), battery management system (BMS) ECU, hybrid power control unit (HPCU), hybrid drive motor, hybrid starter generator (HSG), electric A/C compressor, low DC/DC converter (LDC), power cable, etc. Please be sure to follow the safety instructions below to prevent serious injury or electrocution.
High-Voltage Components:
Safety Warnings:
1. Warning labels are attached to all the high-voltage components and the high-voltage cables and connectors are orange colored. Do not touch any of these high-voltage components, cables and connectors without proper protective gear.
2. Put "WARNING: HIGH VOLTAGE" plate on YF HEV's roof to warn the people around the vehicle of danger before service.
3. For your safety before or while repairing YF HEV:
^ Wear protective gear (insulating gloves and safety glasses).
^ Make sure that gloves & glasses are not torn/broken and that the gloves are dry.
^ Do not carry any metallic objects (clock, ring. Etc.), which can cause short circuit. Use insulated tools.
4. Be sure to remove the service disconnect plug from the high-voltage battery pack according to the below procedures before carrying out any YF HEV high voltage system component service
4.1 Turn the ignition switch OFF and disconnect the auxiliary 12V battery negative cable.
4.2 Locate the service disconnect plug (A: inside of the trunk) and then remove the service disconnect plug service cover (B).
4.3 Lift the locking hook (C), rotate the lever (D) in the arrow direction and then pull out the service disconnect plug (E).
4.4 Wait for 5-10 minutes so that the inverter capacitor can be discharged.
4.5 Measure the voltage between the inverter positive and negative power cable terminals to check that the high voltage circuit is disconnected.
4.5.1 Remove the rear seat and the partition tray trim (F)
4.5.2 Remove the high voltage front cover (G).
4.5.3 Measure the voltage between the inverter (+) and (-) power cable terminals (H).
^ Below 30V: Properly Disconnected
^ More than 30V: Faulty High Voltage
5. Be sure to follow the below instructions when repairing the power cable.
^ Check the voltage of the high voltage connector, terminals or busbar before repairing. Below 30V: High Voltage Circuit Properly Disconnected, More than 30V: Faulty High Voltage Circuit
^ Be careful of short circuits between positive and negative terminals.
^ Insulate the high voltage connector or terminals with insulation tape after disconnecting.
^ Tighten the high voltage terminals with the specified torque using the shop manual.
6. The high-voltage battery must be always handled horizontally during repair or storage, otherwise the battery performance can deteriorate or its life may be shortened.
7. Exposing the high-voltage battery to intense heat may cause deterioration. Do not bake over 70°C (15°F) /30 minor 80°C (176°F) /20 min when painting.