W/Harness Inspection

HEV Battery System

P1B76 High Voltage Relay Fault - Inspection/Repair:_:W/Harness Inspection

Terminal & Connector Inspection

1. Many malfunctions in the electrical system are caused by poor harness and terminals.
Faults can also be caused by interference from other electrical systems, and mechanical or chemical damage.
2. Thoroughly check connectors for looseness, poor connection, bending, corrosion, contamination, deterioration, or damage.
3. Has a problem been found?






Inspection of the high voltage relay for hybrid battery

Inspection of the high voltage relay for hybrid battery
1. Turn Ignition OFF.
2. Pull the Safety Plug and wait 5 Mins.
3. Connect a Voltmeter between the (+) terminal and the (-) terminal from high voltage relay assembly.
4. Plug the Safety Plug in.
5. Ignition ON/Hybrid Ready (Cluster Indicator "READY" On).
6. Check the voltage between the (+) terminal and the (-) terminal from High Voltage Relay assembly.
7. Ignition OFF.
8. Pull the Safety Plug and then confirm the voltage of the terminals is less than 30 V.
9. After taking off the power relay assembly from battery pack, inspect whether every relay (+main relay, -main relay, precharge relay) in PRA is short or not via connecting voltmeter.

Specification : At No.6 step: within specification : about 200 - 310 V,
At No.9 step: within specification : Infinity resistance value (Shorted, replace PRA)

WARNING:
** Warning & Notice
Hybrid Battery system uses around 270 V voltage.
It may cause death or damage due to electrical shock, if you do not follow below Instructions.
▪ Follows instructions of workshop manual.
▪ Wear and use insulated gloves and tools.
▪ IG "OFF", Disconnect ground cable of auxiliary battery and "OFF" the safety connector of the high voltage battery.
▪ Check high voltage terminal on Power Relay Assembly is lower than 30 V.
▪ Be careful that it should not be short between terminals when measuring battery cell voltage. You may be injured due to spark, parts damage or electrical shock.
▪ Metallic material cause high voltage short that may cause damage of life or vehicle. Therefore, get rid of all the metallic material before working. (Metallic Material : Watch, Ring, any metallic products etc.)
▪ After disconnect W/H goes to BMS ECU from High voltage battery, be careful not to happen short between exposed terminal and terminal on high voltage connector.








































10. Are measured value within specification?