Kia Soul EV: High Voltage Battery Control System / Safety Plug Repair procedures

Kia Soul EV (PS EV) 2015-2020 Service Manual / EV Battery System / High Voltage Battery Control System / Safety Plug Repair procedures

Inspection
   
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 shut off the high voltage before doing any work related with the high voltage system(Refer to "High Voltage Shut-off Procedure"). Failure to follow the safety instructions may result in serious electrical injuries.
1.
Remove the safety plug. (Refer to "Removal")
2.
Check the safety plug by visual check and electrical test.
- Check the interlock switch and terminal

Removal
   
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 shut off the high voltage before doing any work related with the high voltage system(Refer to "High Voltage Shut-off Procedure"). Failure to follow the safety instructions may result in serious electrical injuries.
[Safety Plug]
1.
Turn the ignition swtich OFF and disconnect the auxiliary battery negative (-) terminal.
2.
Remove the cover (A) on the floor carpet of the rear seat.

3.
After loosening the nut, remove the safety plug service cover (A).

Safety plug service cover mounting nut : 0.8 ~ 1.2 kgf.m

4.
Remove the safety plug (A).

   
Remove the safety plug in the following order.

[Safety Plug Cable]
1.
Turn the ignition switch OFF and disconnect the auxiliary batter negative (-) terminal.
2.
Shut off the high voltage.
(Refer to Battery Control System - "High Voltage Shut-off Procedure")
3.
Remove the high voltage upper case.
(Refer to High Voltage Battery System - "Case")
4.
Disconnect the safety plug cable inerlock connector (A).

5.
After loosening the nunt (A), remove the safety plug cable assembly (B).

Safety plug cable assembly mounting nut : 0.8 ~ 1.2 kgf.m

Installation
   
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 shut off the high voltage before doing any work related with the high voltage system(Refer to "High Voltage Shut-off Procedure"). Failure to follow the safety instructions may result in serious electrical injuries.
1.
Install the safety plug in the reverse order of removal.
Safety Plug Schematic Diagrams
System Circuit Diagram Circuit Diagram ...

Main Fuse Specifications
Specification ItemSpecificationRated Voltage (V)450 (DC)Rated Current (A)250 (DC) ItemSpecificationRemarkSafety Plug Cable Resistance (?)Less than 1 (20°C)Checkable by multi testerMain Fu ...

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