KIA Niro: Precautions to take before servicing high voltage system
Warning
Hybrid vehicles have high voltage batteries. Incorrect handling of high voltage system or vehicle may lead to serious accident including electric shock and electric leakage.
Warning
- Be sure to shut off the high voltage by removing the safety plug before performing inspection or repairing the high voltage system.(Refer to "High Voltage Shut-off Procedures")
- Keep the safety plug completely removed to prevent the plug from being connected by mistake.
- Do not wear metallic objects (watch, ring etc.) while working on the high voltage system, due to risk of serious accidents like electric shock.
- Whenever working on the high voltage system, wear personal protective equipment to prevent accidents. (Refer to "Personal Protective Equipment")
- Technicians not wearing personal protective equipment must not be allowed to work on high voltage systems. Cover high voltage components with an insulated sheet to prevent accidents.
- Use insulation tools when working on the high voltage system.
- Put the removed high voltage components on the insulation mat.
Warning
- All the high voltage wiring and connectors are orange.
- A caution label for high voltage is attached to the high voltage components.
- High voltage components include: 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), On-Board Charger (OBC), Power Cable, Electric Compressor, etc.
Warning
To prevent injury to technician, place "High Voltage" caution sign as shown.
Personal Protective Equipment
Insulation
gloves 
Used when inspecting or
working on the high voltage components
(Insulation performance : 1000V / 300A or above)
Insulation
shoes 
Insulation clothes 
Used when
inspecting or working on the high voltage components
Insulation
helmet 
Safety
glasses 
Face shield 
Used in the following cases :
-
During removal & installation or inspection of the high voltage
battery terminals or wiring, where spark might happen. -
When working on the high voltage battery pack assembly.
Insulation
mat 
All removed high voltage
components are placed on an insulation
mat to prevent accident.
Insulation
sheet 
Insulation sheet is used to
cover high voltage components to
protect people not wearing personal protective equipment from
accident.
Warning
tape 
Used for informing that it is
dangerous past this line.
READ NEXT:
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.
Warning
Fold the insulation glove as above
Fold again 3~4 times
High Voltage Shut-off Procedures
Warning
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.
Be sure to
Protection Of The Vehicle
Always be sure to cover fenders, seats, and floor areas before starting work.
Warning
The support rod must be inserted into the hole near the edge of the
hood whenever you inspect the
engine compartment to prevent the hood from falling and causi
SEE MORE:
Roof Rack Repair procedures
Replacement
Warning
Put on gloves to protect your hands.
Warning
Use a plastic panel removal tool to remove interior trim pieces
without marring the surface.
Be careful not to bend or scratch the trim and panels.
Remove the roof rac
Electric A/C Compressor
Electric A/C Compressor body inside inspection
Electric compressor body inside check procedure.
1) Remove the low-pressure pipe from the electric compressor.
2) Check if the copper wire and white thread inside of the compressor was
contamin
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