Safety Precaution
This hybrid system uses a DC 270V voltage system. Be sure to follow safety instructions below. Failure to follow safety instructions may result in serious injury or electrocution.
| WARNING | A caution label for high voltage is attached to the high voltage components. The color of the high voltage cables and connectors are orange. Do not touch any of these high voltage components, cables, and connectors without proper Personal Protection Equipment (PPE). |
Note. High Voltage Component: High Voltage Battery Pack Assembly, Power Relay Assembly (PRA), BMS ECU, Hybrid Power Control Unit (HPCU), Hybrid Drive Motor, HSG, Electric A/C Compressor, Low DC/DC Converter (LDC), Power Cable, Electric Compressor etc.
| WARNING | For your safety when servicing the hybrid vehicle: Wear Personal Protection Equipment (Insulation Gloves and Safety Glasses). Do not carry any metallic object (watch, ring etc.) which can cause short circuit. Use insulated tools Before wearing the protective gear, make sure that they are not torn or broken and free of moisture. |
Note. Personal Protection Equipment: Insulating Gloves, Safety Glasses
Insulating Gloves Safety Glasses
Scheme 612
Scheme 613
| WARNING | Use Mega Ohm Tester when measuring insulation resistance of the high voltage system. |
Specification: High Impedance Digital Volt / Ohm Meter (DVOM) "Category 3"
Leads and Meter rated to 1, 000 voltage.
| WARNING | Be sure to shut off the high voltage circuit shown in the procedures below before working on any high voltage system component (Refer to " HIGH VOLTAGE SHUTOFF PROCEDURE " for more detailed procedures). |
Scheme 614
- Turn the ignition switch off and disconnect the auxiliary 12V battery negative (-) cable.
- Remove the safety plug (Turning the ignition switch ON with the safety plug removed may damage the hybrid control system).
- Wait for more than 5 minutes so that the capacitor in the high voltage system can be naturally discharged.
- Remove the rear seat and partition tray trim (Refer to «"PACKAGE TRAY TRIM REPLACEMENT»(ref-535757-S35690240582013031200000)
- Remove the high voltage front cover (A). Measure the voltage between the inverter positive and negative power cable terminals.
Below 30V: High voltage circuit properly shut
More than 30V: High voltage circuit faulty
| CAUTION | Attach the 'High Voltage Caution Car Topper' to the vehicle roof to inform other people of danger of high voltage. |
Scheme 615
Scheme 616
| WARNING | Be sure to follow instructions below when repairing the high voltage cable. |
- Check the voltage of the high voltage connector, terminal or busbar before repairing. Below 30V: High voltage circuit properly shut More than 30V: High voltage circuit faulty
- Be careful not to short circuit between positive (+) and negative (-) terminals.
- Insulate the high voltage connector or terminal with an insulation tape after disconnecting.
- Tighten the high voltage terminal with the specified torque.
| CAUTION | The high voltage battery must be always handled horizontally during repairing or storage. Otherwise, there may be decline in battery performance or its life may be shortened. |
| CAUTION | Exposing the high voltage battery to intense heat may cause deterioration. Do not bake over 70°C (158°F) / 30 min or 80°C (176°F) / 20 min when painting. |
Hybrid Vehicle Refrigerant Recovery / Charging Precautions
- Since the electric compressor uses high-voltage, you should use PVE oil which have high Volumetric Resistivity.
- Do not use the same A/C recovery / charging station as conventional belt-driven compressors.
| WARNING | If the PVE oil of the system gets mixed PAG oil, then dielectric breakdown due to decreased volumetric Resistivity can occur and inoperative A/C compressor may result, A/C compressor may not work. |
High Voltage Shutoff Procedure
| WARNING | Shut off the high voltage circuit before doing any work related with the high voltage system (Battery Pack Assembly, Power Relay Assembly, HPCU, BMS ECU, Hybrid Drive Motor, Inverter, HSG, LDC Power Cable, Electric Compressor, and so on). |
Scheme 617
Scheme 618
Scheme 619
Scheme 620
Scheme 621
- Turn the ignition switch OFF and disconnect the auxiliary 12V battery negative (-) cable.
- Remove the safety plug. Open the safety plug service cover (A). Pull out/down the lever (A) in the direction of the arrow after lifting the locking hook (B), and then pull the safety plug.
- Wait for more than 5 minutes so that the capacitor in the high voltage system can be naturally discharged.
- Make sure that the capacitor has been discharged. Remove the rear seat and partition tray trim (Refer to " «"PACKAGE TRAY TRIM REPLACEMENT»(ref-535757-S35690240582013031200000) Remove the high voltage front cover (A). High voltage front cover installation bolt: 7.8 ~ 11.8N.m (0.8 ~ 1.2kgf.m, 5.8 ~ 8.7lb-ft) Measure the voltage between the inverter positive and negative power cable terminals. Below 30V: High voltage circuit properly shut More than 30V: High voltage circuit faulty WARNING: If the measured voltage is more than 30V, check the removal of the safety plug again. If it is above 30V even though the safety plug is properly removed, there must be any serious problem in high voltage circuit. In this case, do the DTC troubleshooting first (Refer to appropriate Diagnostic Information ); don't do any work related to the high voltage system.
Input Speed Sensor
Type: Hall effect sensor
Specifications
| Operation condition (°C)°F | ((-)40 ~ 150)) -40 ~ 302 | |
|---|---|---|
| Air gap(mm)in. | (0.95 ~ 1.55)0.950 ~ 1.55 | |
| Output voltage(V) | High | 0.3 ~ 7.5 |
| Low | 0.7 ~ 1.4 | |
Output Speed Sensor
Type: Hall effect sensor
Specifications
| Operation condition (°C)°F | ((-)40 ~ 150)) -40 ~ 302 | |
|---|---|---|
| Air gap(mm)in. | (0.25 ~ 1.90) 0.098 ~ 0.0748 | |
| Output voltage(V) | High | 0.3 ~ 7.5 |
| Low | 0.7 ~ 1.4 | |
Oil Temperature Sensor
Type: Negative thermal coefficient type
Specifications
| Temp. (°C)°F | Resistance (kohms) |
|---|---|
| (-40)-40 | 46.8 |
| (-20)-4.0 | 15.6 |
| (0)32.0 | 5.88 |
| (20)68.0 | 2.51 |
| (40)104.0 | 1.17 |
| (60)140.0 | 0.59 |
| (80)176.0 | 0.32 |
| (100)212.0 | 0.18 |
| (120)248.0 | 0.11 |
| (140)284.0 | 0.07 |
| (165)329.0 | 0.43 |
Inhibiter Switch
Type: Combination of output signals from 4 terminals
Specifications
| Power supply (V) | 12 |
|---|---|
| Output type | Combination of output signals |
Electric Oil Pump (EOP)
Specifications
| Pump | Pumping capacity | About 6.46cc per one revolution |
|---|---|---|
| Type | Internal gear | |
| Motor | Type | Brushless DC motor (3 phases) |
| Torque | Rated 1.5 N.m | |
| Speed range | 100 ~ 2, 500 rpm |
Oil Pump Unit (OPU)
Specifications
| Operating voltage (V) | 12 |
|---|---|
| Current | 15 ~ 20A (normal), 30A |
Direct control VFS [26/B, E/C]
Control type: Normal low type
| Control Pressure kpa (kgf/cm 2 , psi) | 9.81 ~ 500.14 (0.1 ~ 5.1, 1.42 ~ 72.54) |
|---|---|
| Current value (mA) | 50 ~ 850 |
| Internal resistance (ohms) | 5.1 |
Direct control VFS [UD/B, OD/C, 35R/C]
Control Type: Normal high type
| Control Pressure kpa (kgf/cm 2 , psi) | 500.14 ~ 9.81 (5.1 ~ 0.1, 72.54 ~ 1.42) |
|---|---|
| Current value (mA) | 50 ~ 850 |
| Internal resistance (ohms) | 5.1 |
Line Pressure Control VFS
Control type: Normal high type
| Control Pressure kpa (kgf/cm 2 , psi) | 500.14 ~ 9.81 (5.1 ~ 0.1, 72.54 ~ 1.42) |
|---|---|
| Current value (mA) | 50 ~ 850 |
| Internal resistance (ohms) | 5.1 |
ON/OFF Solenoid Valve (SS-A, SS-B)
Control type: Normal low type
| Control pressure kpa (kgf/cm 2 , psi) | 490.33(5.0, 71.12) |
|---|---|
| Internal resistance (ohms) | 10 ~ 11 |
Lubricants
| Item | Specified lubricant | Quantity |
|---|---|---|
| Transaxle fluid | SK ATF SP-IV, MICHANG ATF SP-IV, NOCA ATF SP-IV, Kia Genuine ATF SP-IV | 6.5L (1.72 U.S gal., 6.87 U.S.qt., 5.74 lmp.qt.) |
Sealant
| Item | Specified sealant |
|---|---|
| Rear cover | LOCTITE FMD-546(P/N: UM010CH046) or equivalent or THREE-BOND TB1281B |
| Motor housing |
Special Service Tools
Tools (Number and name) Illustration Use 09200-38001 Engine support fixture Removal and installation of the transaxle. 09452-3D100 Oil seal installer Installation of transaxle case oil seal. [Using with handle (SST No.:09231-H1100)] 09231-H1100 Bar Installation of transaxle case oil seal. [Using with oil seal installer (SST No.:09452-3D100)]
