Kia OPTIMA plug-in hybrid User manual

Emergency Rescue Guide Manual

Introduction
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Optima Plug
-in Hybrid Electric Vehicle Identification .. . . . . . . . . . . . . .
General Vehicle Description
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Identifying a Kia Optima Plug
-in Hybrid Electric Vehicle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Optima PHEV Main Electric Systems
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Power Electric Specification
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Vehicle
Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Airbag system (SRS: Supplemental Restraint System). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Roadside Assistance
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Towing
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To Jump Start the Car
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Contents
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Document Purpose
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Vehicle Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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Emergency Procedures
Initial Response: Identify, Immobilize and Disable
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Extraction Operations
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Vehicle Fire
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Submerged or Partially Submerged Vehicles
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High Voltage Battery Damage and Fluid Leaks
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NO
-CUT ZONES. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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Document Purpose
The purpose of this document is to familiarize first responders and the towing/roadside
assistance industry with the proper methods to handle the
Optima Plug-in Hybrid Electric
Vehicle
in an emergency situation. This guide gives a basic overview of key vehicle
systems and instructions for dealing with the different types of emergencies encountered
by first responders.
The emergency response procedures for this vehicle will be somewhat
similar to that of a conventional Optima, with additional information provided on dealing
with the high voltage electrical system.
1
Introduction
Within this Emergency Response Guide you will find
Notices , Cautions , Warnings
and
Dangers which provide critical information and help you do your job safely and
efficiently. Below are the definitions of these terms. When you see a
Notice , Caution ,
Warning
or Danger , be certain you understand the message before you attempt to
perform any part of an emergency response procedure.
A Notice alerts you to a situation which, if not avoided, could result in vehicle damage.
A Caution alerts you to a hazardous situation which, if not avoided, could result in minor or
moderate injury.
A Warning alerts you to a hazardous situation which, if not avoided, could result in death
or serious injury.
A Danger alerts you to a hazardous situation which, if not avoided will
result in death or serious injury.

2
Introduction
Vehicle Description
As with other PHEV, the Kia Optima PHEV uses the combination of a conventional gasoline
powered internal combustion engine and a High Voltage battery & electric motor to propel
the vehicle. This combination provides for improved gas mileage over a conventional Kia as
well as an increase in power over the standard 4
-cylinder engine.
Unlike HEV, Optima PHEV’s High Voltage battery can be recharged through the charge port
on the left fender. This increases fuel efficiency and EV mode driving range. The High
Voltage battery is also automatically recharged while driving. This is accomplished through
the engine and regenerative braking system that produces electricity while driving and
braking.

General Vehicle Description
The Kia Optima Plug
-in Hybrid Electric Vehicle can be easily identified by the “Eco plug-
in”
logo attached on the trunk lid and side of the vehicle.
3
Optima HEV Identification
Identifying a Kia Optima Plug
-in Hybrid Electric Vehicle
“Eco
plug-in” logo on trunk and side of vehicle
The hybrid logo can become hidden after a crash due to damage to the vehicle. Always be
sure to use additional methods of identification before determining the vehicle is not a
hybrid.
Electrocution Risk
The Kia Optima
Plug-in Hybrid Electric Vehicle is built on the conventional Optima chassis
and therefore the vehicle looks very similar
to its conventional counterpart with a few
notable exceptions. The safest method is to assume that any Optima you respond to is a
Plug
-in Hybrid Electric Vehicle until proven otherwise. Using the information provided in
this section, responders will be able to differentiate between the two.

The VIN (Vehicle Identification Number) identifies
the Plug-in Hybrid Electric Vehicle
with a
“D” in the 8th digit, as shown below.
The VIN can be found:
1) Underneath the front passenger seat (or driver seat).
2) On the vehicle certification label attached to the driver’s side (or passenger) center pillar.
4
Optima HEV Identification
VIN number
XXXXXXXDXXXXXXXXX
8th digit

An “Eco Plug
-in Hybrid” logo is also displayed on the engine cover under the hood. Also,
the High Voltage cabling is orange per SAE standard. Orange cables run under the vehicle
from the High Voltage Battery to the Hybrid Power Control Unit (HPCU), Motor, Inverter,
and other High Voltage components in front of the vehicle.
The presence of orange cables under the hood identifies the vehicle as an Electric Vehicle.
5
Optima PHEV Identification
Engine
Room

The charging port is located on the front
left fender and it has one port for AC normal
charging.
Note : The doors must be un
-locked to open the charge port door.
6
Optima PHEV Identification
Charging Port
How to open the charging port
1.
Depress the brake pedal and apply the
parking brake.
2.
Turn OFF all switches, move the shift lever
to P (Park) and turn off the vehicle.
3. Open the charging door by pressing it.
Unlock
charging door in emergency
If the charging door does not open due to
battery discharge, open the hood and
slghtly
pull the emergency cable as shown left.
The charging door will then open.

The Plug
-in Hybrid Electric Vehicle (PHEV) Instrument Cluster has specific features to
identify the Optima as a PHEV. Those features are circled below in red.
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Plug-in Hybrid Electric Vehicle Instrument Cluster
Optima PHEV Identification
Energy Flow
The High Voltage battery Charge Status Indicator
is visible from outside the vehicle. It is seen
through the windshield at the center of the crash
pad and is illuminated when the vehicle is
plugged
-in and charging.
Charge Status Indicator

8
Optima PHEV Main Electric Systems
Power
Electric Specification
High-voltage battery
Hybrid Starter
Generator (HSG)
Motor
Transmission
Motor
Type Permanent Magnet Synchronous Motor
Max. Output HP(kW) 67 (50)
Max. Torque lb-ft(Nm) 151 (205)
HPCU
Inverter Input Voltage(V) 200 ~ 310
LDC Max. Output HP(kW) 2.4 (1.8)
High Voltage
Battery
Type Lithium-Ion Polymer
Rated Voltage (V) 360
Capacity (Ah) /
Energy (kWh) 27.2 / 9.8
Cells 96
Power (kW) 68

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Optima PHEV Main Electric Systems
Vehicle
Components
12V
Auxiliary Battery
The 12V auxiliary battery, located in the right hand side of the trunk, powers all of the
vehicle’s standard electronic
systems such as radio and
air conditioner. Also, it powers the
HPCU (Plug
-in Hybrid Power Control Unit) which controls high voltage current to main
electric systems like the motor.
12V Auxiliary Battery

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Optima PHEV Main Electric Systems
Motor
The electric motor drives the vehicle and produces
67HP (50
kW) and 151lb-ft (205 Nm) torque.
Hybrid Power Control Unit (HPCU)
The HPCU integrates an Inverter and LDC (Low Power
DC-DC Converter) in one housing. The inverter
converts DC to AC to supply electricity to the motor.
It also converts AC to DC to charge the high voltage
battery. The LDC converts High Voltage AC electricity
to Low Voltage DC to charge 12V auxiliary battery.
High Voltage Battery System
The High Voltage battery stores electricity and supplies
it to the traction motor. It is a Lithium ion polymer
battery with specifications, 360V / 27.2Ah / 9.8 kWh. It
is located in the trunk of the Optima PHEV.
Hybrid Starter Generator (HSG)
The
HSG restarts the engine in HEV mode and also
charges the high voltage battery
–the generator for Plug-in Hybrid
vehicle
- while driving.

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Optima PHEV Main Electric Systems
High Voltage Orange Cabling
The High Voltage cabling is orange per SAE standard. Orange cables run under the floor
of the vehicle and connect the High Voltage battery to the HPCU, Motor, LDC, Inverter,
OBC and other High Voltage components in front of the vehicle.
Orange cables or Orange shielding underhood, under-floor or in the battery compartment
identify the vehicle as an electric vehicle.
 Never cut or disconnect the high voltage orange cabling and connectors without first
disabling the system by removing the safety plug.
 Exposed cables or wires may be visible inside or outside the vehicle. Never touch
the wires, cables, connecters, or any electric components before disabling the
system, to prevent injury or death due to electrical shock.
Failure to follow these instructions can lead to death by electrical shock.
High Voltage Cables
The
OBC is the battery charging equipment that
converts external AC to DC to charge the high voltage
battery.
On
-Board Charger (OBC)

12
Optima PHEV Main Electric Systems
Airbag
system (SRS: Supplemental Restraint System)
Air
bag
Seven airbags are installed in standard areas of the Optima Plug
-
in Hybrid Electric Vehicle
so first responders can find them immediately.
Before emergency procedure, make sure
that the vehicle ignition is switched off, and disconnect the negative cable from the 12V
auxiliary battery to prevent accidental deployment of
undeployed airbags.
Seatbelt
Pretensioner
The Optima Plug
-in Hybrid Electric Vehicle is equipped with driver side
and front passenger
side
seatbelts with pretensioners. When the seatbelt pretensioners are activated in a
collision, a loud noise may be heard and fine dust, which may appear to be smoke, may be
visible in the passenger compartment. These are normal operating conditions and are not
hazardous. The seatbelt
pretensioner assembly mechanisms may become hot during
activation, and may need several minutes to cool after they have been activated.
❈
The actual airbags and seats in the vehicle may differ from the illustration.
(1) Driver side front airbag
(2) Passenger side front
airbag
(3) Side airbag
(4) Curtain airbag
(5) Driver side knee airbag

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Optima HEV Main Electric Systems
Airbag System
Components
1.
Driver Airbag (DAB)
2.
Steering Wheel
3.
Clock Spring
4.
Seatbelt Pretensioner (BPT)
5.
Side Impact Sensor (SIS)
6.
Side Airbag (SAB)
7.
Passenger Airbag (PAB)
8.
Front Impact Sensor (FIS)
9.
Curtain Airbag (CAB)
10.
Supplemental Restraint System Control
Module (SRSCM)
11.
Airbag Warning Lamp
12, 14.
Emergency Fastening Device (EFD)
13, 15.
Pressure Side Impact Sensor (PSIS)
To avoid injuries caused
by accidental deployment of undeployed airbags

Do not cut the red colored part on the above layout.

Make sure the vehicle ignition is turned off, disconnect the negative cable from the
12V auxiliary battery, and wait 3 minutes or longer to allow the system to
deactivate.
Failure
to follow any of these instructions may result in serious injury or death from
accidental deployment of the airbag system.
Undeployed
Airbags

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Emergency Procedures
Initial Response: Identify, Immobilize and Disable
Identify
When dealing with an Optima at an emergency scene, emergency responders should
always assume that it is a Plug
-in Hybrid Electric Vehicle (PHEV) until it can be proven
otherwise, using the identification clues outlined in this ERG. External logos will usually be
the first clues but they can often be hidden from sight by damage caused in a crash.
Always be sure to visually check all sides of the vehicle and
use clues found under the
hood and in the interior of the vehicle.
The following procedures should be used whenever you are dealing with an Optima Plug-in
Hybrid Electric Vehicle at an emergency scene. All other operations should be consistent
with your department’s standard operating procedures or guides. Plug-in Hybrid Electric
Vehicles damaged by a crash may have compromised High Voltage safety systems and
present a potential High Voltage electrical shock hazard. Exercise caution and wear
appropriate Personal Protective Equipment (PPE) safety gear, including High Voltage safety
gloves and boots. Remove all metallic jewelry, including watches and rings.

15
Emergency Procedures
Immobilize
The next step is to immobilize the vehicle to prevent any accidental movement that can
endanger response personnel and civilians alike. Although the Optima Plug
-in Hybrid
Electric Vehicle emits a virtual engine sound, if it is damaged from crash, there may be
instances where the vehicle appears to be shut off due to no engine sound.
When the "READY" lamp in the instrument cluster is illuminated, the vehicle can
move silently using the electric motor. Responders should approach the vehicle from the
sides and stay away from the front or rear as they are potential paths of travel. Immobilize
the vehicle with the following procedure.
Chock the wheels. Set the parking brake.
Shift lever in park “P”.

16
Emergency Procedures
Disable
After the vehicle is secured to prevent movement, the final step in the initial response
process is to disable the vehicle, its SRS components and the high voltage electrical system.
To prevent current flow through the system, use one of the following procedures to disable
the vehicle.
I . Disabling the System
–
Smart Key System and “POWER” START/STOP Button
1. Check the status of the READY light on the
instrument panel. If the READY light
is illuminated, the vehicle is on.
a) If the READY light is NOT
illuminated, the vehicle is off. Do not
push the “POWER” START/STOP
button as this may start the vehicle.
b) To turn off the system, move the shift lever to Park "P" and press the POWER button.
With brake pedal released
Press POWER
button
POWER
button
LED color Vehicle condition
Off Off
One time Amber Electrical accessories are
operational.
Two times Reddish orange The warning lights can be checked
before the vehicle is started.
Three times Off Off
While depressing the brake pedal while a shift lever is in the P (Park) position
Press POWER
button
POWER
button
LED color Vehicle condition
Off Off
One time Off Ready to drive
“POWER” START/STOP Button

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Emergency Procedures
2. If necessary, lower the windows, unlock the doors and
open the trunk as required, before disconnecting the
12V battery. Once the 12V battery is disconnected,
power controls will not operate.
3. Before disconnecting 12V battery, move the Smart Key
at least 2 meters away from the vehicle to prevent
accidental restart.
Smart key
4. Disconnect the negative (
-) 12V battery cable, located in the trunk, to further
prevent the risk of accidental restart.
5. Remove the safety plug and disable the high voltage battery in the following
procedure:
a) Remove the luggage cover board and the side luggage
foam in the trunk.
b) Remove the safety plug cover (B)
by loosening the mounting bolts (A).
c) Unfasten the hook (A) to the
direction of arrow.
d) Unfasten the lever (A).
e) Remove the safety plug (A).

18
Emergency Procedures
1. Open
the hood.
II. Disabling the System
–IG (Ignition) Fuse Removal
2. Remove the engine room fuse box
cover.
3. If necessary, lower the windows,
unlock the doors and open the trunk
as required, before disconnecting the
12V battery. Once the 12V battery is
disconnected, power
controls will not
operate.
4. In the event the vehicle cannot be
disabled using the “Power”
START/STOP Button, pull the Multi
Fuse A and B along with IG3 Relay
from the engine room fuse box. If
the IG Relay cannot be located,
pull out all the fuses and relays in
the fuse box.
5. Disconnect the negative (-) 12V battery cable, located in the trunk, to further prevent
the risk of accidental restart.
Before disconnecting the 12V battery (if needed), lower the windows, unlock the doors
and open the trunk as required. Once the 12V battery is disconnected, power controls will
not operate.
Multi Fuse
A B
IG3
Relay