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HIGH VOLTAGE BATTERY HANDLING GUIDE

High Voltage Battery System Inspection Procedure Per Inspection Type In Case Of An Accident On
Electric Vehicle

• When working on the voltage system, make sure that you are familiar and comply with the "Safety Precautions,
Cautions and Warnings." If you do not comply with the instructions, serious accidents due to electric shock or
leakage may occur.
• When working on the high voltage system, make sure to cut off the high voltage first according to the "High
Voltage Cut-off Procedure." If you do not comply with the instructions, serious accidents due to electric shock or
leakage may occur.

1. After the exterior inspection, determine if it should be repaired as a general failure or accident damage.

2. Comply with the repair procedure by DTC code for general failure repair.

3. Identify the type of accident as follows and proceed with the vehicle repair after an accident.

1) Electrical Accidents

– Overcharging/Overdischarging : Battery Over Voltage (P0DE7)/Under Voltage (P0DE6) Code Display (refer to the DTC
Diagnosis Guide)
– Short Circuit : High voltage fuse disconnection-related diagnosis (P1B77, P1B25) code display (refer to DTC Diagnosis
Guide)

2) Fire Accidents
Classification Inspection procedure Inspection Results Remedy

1. Exterior Inspection (Deformation, Insulate it or wrap the

High Voltage Battery Insulation
rust, wiring sheath, smell and insulator after removing the
Breakdown and Damage
connector) high voltage battery

2. Check the main fuse for

disconnection after cutting off the
High Voltage high voltage. If a DTC code occurs, follow
Battery Fire in (Refer to the "High Voltage Cut-off DTC occurred the inspection guide repair
unmounted parts Procedure") procedure
3. High Voltage Main Relay Welding High Voltage
※ e.g., Vehicle
Status Inspection Battery Not
Engine Room
Fire Damaged
4. Measure the high voltage High Voltage Battery Not
battery/chassis insulation resistance Replaced (if the vehicle is
DTC not occurred damaged almost to the level
5. Check for other part failure and the battery to be scrapped, proceed
exterior normal with the high voltage battery
6. Check the DTC code of the BMS
disposal procedure if
ECU.
necessary)
High Voltage 1. Exterior Inspection (Deformation, After removing the service
Battery Fire in rust, wiring sheath, smell and High Voltage Battery Exterior plug, soak it in the salt water
mounted parts connector) Damage to proceed with the high
(Heat marks, soot, etc.) voltage battery disposal
※ e.g., Trunk procedure.
Compartment 2. High Voltage Battery Exterior Insulate it or wrap the
Fire High Voltage Battery Insulation
Damage Inspection insulator after removing the
Breakdown
high voltage battery
3. If the high voltage battery exterior is
not damaged, cut off the high If a DTC code occurs, follow
voltage, and check for the high DTC occurred the inspection guide repair
voltage main relay welding condition. procedure
(Refer to the "High Voltage Cut-off
Procedure") High Voltage High Voltage Battery Not
Battery Not Replaced (if the vehicle is
4. Measure the high voltage Damaged DTC not occurred damaged almost to the level
battery/chassis insulation resistance
Battery Exterior to be scrapped, proceed
5. Check for other part failure Normal with the high voltage battery
disposal procedure if
6. Check the DTC code of the BMS necessary)
ECU.

3) Collision Accidents
Classification Inspection Method Inspection Results Remedy

1. Exterior Inspection (Deformation, rust, High Voltage Battery Insulate it or wrap the insulator
wiring sheath, smell and connector) Insulation Breakdown and after removing the high voltage
Damage battery
2. Check the main fuse for disconnection
High Voltage after cutting off the high voltage.
Battery (Refer to the "High Voltage Cut-off If a DTC code occurs, follow the
Collision of Procedure") DTC occurred inspection guide repair
unmounted
procedure
parts 3. High Voltage Main Relay Welding Status
Inspection High Voltage
※ e.g., Battery Not
Front/Side 4. Measure the high voltage Damaged High Voltage Battery Not
DTC not
Collision battery/chassis insulation resistance Replaced (if the vehicle is
occurred and
damaged almost to the level to
5. Check for other part failure the battery
be scrapped, proceed with the
exterior
high voltage battery disposal
6. Check the DTC code of the BMS ECU. normal
procedure if necessary)

1. Exterior Inspection (Deformation, rust, High Voltage Battery

wiring sheath, smell and connector) Insulation Breakdown and
Damage ⇑ Take corrective measures
2. Check the main fuse for disconnection following the same standards
High Voltage after cutting off the high voltage. as above.
Battery (refer to the "High Voltage Cut-off ※ If it is impossible to approach
Collision of Procedure") the part where the high voltage
DTC occurred
mounted battery is installed due to a
3. High Voltage Main Relay Welding Status
parts High Voltage trunk or vehicle door damage,
Inspection
Battery Not deform or cut the exterior of the
※ e.g., Rear 4. Measure the high voltage Damaged vehicle to prevent damage to
Collision battery/chassis insulation resistance DTC not the high voltage system, and
occurred and then perform the inspection or
5. Check for other part failure the battery repair procedure.
exterior
6. Check the DTC code of the BMS ECU.
normal

4) Flooding Accidents
Classification Inspection Method Inspection Results Remedy

High Voltage 1. Exterior Inspection (Deformation, Insulate it or wrap the

High Voltage Battery Insulation
Battery Not rust, wiring sheath, smell and insulator after removing the
Breakdown and Damage
Included connector) high voltage battery
 2. Check the main fuse for
disconnection after cutting off the
high voltage.
(Refer to the "High Voltage Cut-off If a DTC code occurs, follow
Procedure") DTC occurred the inspection guide repair
procedure
3. High Voltage Main Relay Welding
Status Inspection High Voltage
Battery Not
4. Measure the high voltage Damaged
High Voltage Battery Not
battery/chassis insulation resistance
Replaced (if the vehicle is
5. Check for other part failure DTC not occurred damaged almost to the level
Battery Exterior to be scrapped, proceed
6. Check the DTC code of the BMS Normal with the high voltage battery
ECU. disposal procedure if
necessary)

1. Check the main fuse for

disconnection after cutting off the
high voltage.
(Refer to the "High Voltage Cut-off
Procedure")
Corrective measures are taken, Insulate it or wrap the
High Voltage 2. High Voltage Main Relay Welding
regardless of the inspection insulator after removing the
Battery Included Status Inspection
results high voltage battery
3. Measure the battery/chassis
insulation resistance.

4. Check the DTC code of the BMS

ECU.

Main Fuse Inspection

1. Perform the high voltage cut-off procedure.
(Refer to Battery Control System - "High Voltage Cut-off Procedure")

2. Remove the high voltage battery assembly.

(Refer to High Voltage Battery System - "Repair procedures")

3. Remove the high voltage battery assembly upper cover (A).

(Refer to High Voltage Battery System - "Repair procedures")

4. Remove the busbar (A) after loosening the mounting nut.

Service Plug Busbar Mounting Nut :
9.8 - 11.8 N.m (1.0 - 1.2 kgf.m, 7.2 - 8.7 lb-ft)
5. Remove the main fuse cover (A).

6. Remove the main fuse (A).

7. Measure the resistance between the each end of the main fuse.
Specified Value : 1Ω or Under (20°C)

High Voltage Main Relay Welding Condition Inspection

[Diagnostic tool Device - Service Data]

1. Connect the diagnostic tool to the self-diagnosis connector (DLC).

2. Turn ON the ignition switch.

3. Check the BMS welding condition in the diagnostic tool service data.
Specified Value : NO
[Direct Measurement Using a Multimeter]

• When working on the voltage system, make sure that you are familiar and comply with the "Safety Precautions,
Cautions and Warnings." If you do not comply with the instructions, serious accidents due to electric shock or
leakage may occur.
• When working on the high voltage system, make sure to cut off the high voltage first according to the "High
Voltage Cut-off Procedure." If you do not comply with the instructions, serious accidents due to electric shock or
leakage may occur.

1. Perform the high voltage cut-off procedure.

(Refer to Battery Control System - "High Voltage Cut-off Procedure")

2. Remove the high voltage battery system assembly.

 (High Voltage Battery System - "Repair procedures")

3. Remove the high voltage battery pack upper case.

(High Voltage Battery System - "Repair procedures")

4. Remove the PRA top cover (A).

5. Measure the resistance on the high voltage main relay to inspect the weld condition as shown in the figure.

Check The Insulation Resistance Of The High Voltage Battery

[Diagnostic tool Device - Service Data]

1. Connect the diagnostic tool to the self-diagnosis connector (DLC).

2. Turn ON the ignition switch.

3. Check the insulation resistance in the diagnostic tool service data.

Specified Value : 300 - 1000 kΩ
Check The High Voltage Battery Pack Assembly Insulation Resistance (Unit Side)

[Direct Measurement Using an Insulation Resistance Tester (Megohm Tester)]

• When working on the voltage system, make sure that you are familiar and comply with the "Safety Precautions,
Cautions and Warnings." If you do not comply with the instructions, serious accidents due to electric shock or
leakage may occur.
• When working on the high voltage system, make sure to cut off the high voltage first according to the "High
Voltage Cut-off Procedure." If you do not comply with the instructions, serious accidents due to electric shock or
leakage may occur.
1. Remove the high voltage battery system assembly.
(High Voltage Battery System - "Repair procedures")

2. Remove the high voltage battery pack upper case.

(High Voltage Battery System - "Repair procedures")

3. Remove the PRA top cover.

(High Voltage Battery System - "Power Relay Assembly (PRA)")

4. Connect the (-) terminal (A) of the insulation resistance tester to the lower battery case (or the ground part).

• Connect the (-) terminal of the insulation resistance tester to the unpainted part to ensure accurate
measurement.

5. Connect the (+) terminal of the insulation resistance tester to the (+) and (-) sides of the high voltage battery each, and
measure the resistance.
[Measure the insulation resistance value on the high voltage (+) terminal side of the power relay assembly]
(1) Connect the insulation resistance tester (+) terminal (A) to the (+) side of the PRA high voltage power terminal.

(2) Input 500V voltage through the insulation resistance tester, and wait for approx. 1 minute to take a stable resistance
measurement.

(3) Check the insulation resistance value.

Specified Value : 2 MΩ or Greater (20°C)
[Measure the insulation resistance value on the high voltage (-) terminal side of the power relay assembly]
(4) Connect the insulation resistance tester (+) terminal (A) to the (-) side of the PRA high voltage power terminal.

(5) Input 500V voltage through the insulation resistance tester, and wait for approx. 1 minute to take a stable resistance
measurement.

(6) Check the insulation resistance value.

Specified Value : 2 MΩ or Greater (20°C)
[Measure the insulation resistance value on the inverter power (+) terminal side of the power relay assembly]
(7) Connect the insulation resistance tester (+) terminal (A) to the (+) side of the PRA inverter power terminal.

(8) Input 500V voltage through the insulation resistance tester, and wait for approx. 1 minute to take a stable resistance
measurement.

(9) Check the insulation resistance value.

Specified Value : 2 MΩ or Greater (20°C)
[Measure the insulation resistance value on the inverter power (-) terminal side of the power relay assembly]
(10) Connect the insulation resistance tester (+) terminal (A) to the (-) side of the PRA inverter power terminal.

(11) Input 500V voltage through the insulation resistance tester, and wait for approx. 1 minute to take a stable
resistance measurement.

(12) Check the insulation resistance value.

Specified Value : 2 MΩ or Greater (20°C)
High High Voltage Battery System Storage, Transport, and Disposal-related Handling Guide
1. Old High Voltage Battery System Handling Procedure
2. How to Handle/Inspect the Old High Voltage Battery System

Classification Item Measure

Undamaged Battery Storage After removing the service plug, wrap and store safely under the same condition
required for the new battery system.
Transport Transport it separately to minimize the impact and prevent it from being mixed with
other normal parts.
Disposal Transport it to the designated disposal company, discharge it completely using the
salt precipitation method or a discharge device, and then perform the disposal
process of the disposal company.
Damage Common Inspection 1. Voltage Failure Inspection(Using Digital Multimeter)
Battery Items Method (1) Measure the voltage between the upper (+) terminal of the service plug and
the (-) terminal of the [High Voltage Battery-PRA] connection cable = Normal
if 120 - 207.

(2) Measure the voltage between the lower (-) terminal of the service plug and
the (+) terminal of the [High Voltage Battery-PRA] connection cable = Normal
if 120 - 207.
 (3) Measure and check that the voltage between the (+) and (-) terminals of the
high voltage relay connection cable is
Extended type : 245 - 411.6V
Economical type : 225 - 378V
Basic Measuring Conditions : Measure while the service plug is connected.

▶ Measures : Upon an abnormality, immediately discharge it completely using the

salt precipitation method or a discharge device to prevent high voltage battery
fire.

2. Abnormal Temperature Inspection(Using Non-contact Thermometer)

(1) Check the outer temperature of the battery pack case.

(2) Measure the initial temperature/follow-up temperature in 30 minutes, and

then check for potential temperature variations

▶ Normal Criteria: Temperature change of 3°C or less, maximum temperature of

35°C or lower
▶ Measures
– If the max. temperature 35°C is exceeded, leave it in a cool, dry place, and
perform a temperature test at around 35°C.
– If the temperature difference increases by 3°C from the initial temperature in
30 min, discharge it completely using the salt precipitation method or a
discharge device
– If the temperature keeps on increasing when checking it at 30 min intervals,
immediately discharge it completely using the salt precipitation method or a
discharge device.

3. Abnormal Insulation Resistance Inspection(Using Mega Ohm Tester)

(1) Measure the insulation resistance between the power relay (+) terminal and the
battery pack cover
(2) Measure the insulation resistance between the power relay (+) terminal and the
battery pack cover
▶ Normal Criteria : Insulation resistance of 2MΩ or lower (when 500 V voltage is
applied)
▶ Measures : Insulate it or wrap the outer insulator.
4. Insulation for the possible spot of short circuit(Insulating after visual inspection)
(1) High Voltage Battery-PRA Connection Cable Terminal
(2) BMS Voltage Sensing Connector
▶ Measures
- Insulation with a rubber cap or insulation tape is required to prevent short circuit
between the packs, cells and modules.
- The cable terminal should be fixed to minimize the movement.
5. Check for Electrolyte Leakage
- Check the smell directly within a 30cm distance from the battery pack (similar to the
smell of chemical agents or acrylic substances)
▶ Measures : If an abnormal odor that indicates possible electrolyte leakage is
detected, immediately discharge it completely using the salt precipitation method or a
discharge device.

Classification Item Measure

Damage Battery Damaged Battery Storage After removing the service plug, wrap and store under the same
Inspection Result condition required for the new battery system.
: Normal
Transport Transport it separately to minimize the impact and prevent it from
being mixed with other normal parts.
Disposal Transport it to the designated disposal company, discharge it
completely using the salt precipitation method or a discharge
device, and then perform the disposal process of the disposal
company.
 Damaged Battery Storage Remove the service plug. Check the location of the exposed
Inspection Result external terminal and insulate it. Store separately in a cool and dry
: Abnormal place, away from volatile/combustible substances. Insulate the
exterior of the battery pack using an exterior insulation material
(insulation tape, rubber cap, etc.) to prevent disconnection of
external terminals, and fill the package with the insulator (vinyl,
wrap, etc.) to minimize impact.
Transport Transport it separately to minimize the impact and prevent it from
being mixed with other normal parts.
Disposal Transport it to the designated disposal company, discharge it
completely using the salt precipitation method or a discharge
device, and then perform the disposal process of the disposal
company.

Voltage Failure Inspection Procedure

1. Measure the voltage between the upper (+) terminal on the high voltage battery side and the (-) terminal of the [High
Voltage Battery – PRA] connection cable.
Normal Voltage Reading : 120 - 207V

2. Measure the voltage between the lower (-) terminal on the high voltage battery side and the (+) terminal of the [High
Voltage Battery – PRA] connection cable.
Normal Voltage Reading : 120 - 207V
3. Connect the service plug.

4. Measure the combined resistance between the (+) and (-) terminals of the high voltage battery.
Normal Voltage Reading (Extended type) :
245 - 411.6V
Normal Voltage Reading (Economical type :
225 - 378V
Insulation Procedure for the Possible Spot of Short Circuit
1. How to Insulate the High Voltage Battery-PRA Connection Cable Terminal
 – Insulate each of the cable terminals (+) and (-) with a rubber cap or insulation tape to prevent pack short circuit.
– Fix the cable terminal to the battery pack case using a insulation tape to minimize the movement.

2. How to Insulate the BMS Voltage Signal Connector

 – Insulate the connector with a lubber cap or insulation tape to prevent any short circuit between the cells or modules.
– Fix the wiring to the battery pack case using a insulation tape to minimize the movement.

3. High Voltage Battery System Discharge Procedure on Disposal

• When working on the high voltage system, make sure that you are familiar and comply with the "Safety
Precautions, Cautions and Warnings." If you do not comply with the instructions, serious accidents due to electric
shock or leakage may occur.
• When working on the high voltage system, make sure to cut off the high voltage first according to the "High
Voltage Cut-off Procedure." If you do not comply with the instructions, serious accidents due to electric shock or
leakage may occur.

The high voltage battery may cause electric shock and other accidents. If the high voltage battery shows any abnormal
symptom as shown below, immediately discharge the battery using the salt precipitation method (soaking in salt water) at
the service center.
– When there are fire marks or smokes
– When the high voltage battery voltage is abnormally high
(Extended type : 413 V or greater), (Economical type : 388 V or greater)
– When the high voltage battery temperature keeps on increasing abnormally
– In case of unusual smell which indicates possible electrolyte leakage (similar to that of chemical agents or acrylic
substances).
[Salt Precipitation Discharge Method]
1. Pour water into a plastic container (e.g. poly propylene) that can submerge the whole battery

2. Prepare approx. 3.5% salt water by pouring salt into the water.

• For example, If the amount of water is 2.6 gallons (10 liters), the amount of salt is 0.8 pounds (350g).

3. Use the soak the high voltage battery assembly or battery module in salt water as shown below.
 • Use the crane jack to transport the high voltage battery pack assembly.

4. After leaving it for approx. 12 hours, take out the high voltage battery from the basin and dry it.