Emergency Rescue Guide Manual - Kia
Emergency Rescue Guide Manual
ContentsIntroduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1Document Purpose. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1Vehicle Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2Optima Plug-in Hybrid Electric Vehicle Identification . . . . . . . . . . . . . . 3General Vehicle Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3Identifying a Kia Optima Plug-in Hybrid Electric Vehicle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3Optima PHEV Main Electric Systems. . . . . . . . . . . . . . . . . . . . . . . . . . . . 8Power Electric Specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8Vehicle Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9Airbag system (SRS: Supplemental Restraint System). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12Emergency ProceduresInitial Response: Identify, Immobilize and Disable. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1414Extraction Operations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20NO-CUT ZONES. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .21Vehicle Fire . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .22Submerged or Partially Submerged Vehicles. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .22High Voltage Battery Damage and Fluid Leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .23Roadside Assistance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .24Towing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24To Jump Start the Car. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .25
IntroductionDocument PurposeThe purpose of this document is to familiarize first responders and the towing/roadsideassistance industry with the proper methods to handle the Optima Plug-in Hybrid ElectricVehicle in an emergency situation. This guide gives a basic overview of key vehiclesystems and instructions for dealing with the different types of emergencies encounteredby first responders. The emergency response procedures for this vehicle will be somewhatsimilar to that of a conventional Optima, with additional information provided on dealingwith the high voltage electrical system.Within this Emergency Response Guide you will find Notices, Cautions, Warningsand Dangers which provide critical information and help you do your job safely andefficiently. 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 toperform any part of an emergency response procedure.A Danger alerts you to a hazardous situation which, if not avoided willresult in death or serious injury.A Warning alerts you to a hazardous situation which, if not avoided, could result in deathor serious injury.A Caution alerts you to a hazardous situation which, if not avoided, could result in minor ormoderate injury.A Notice alerts you to a situation which, if not avoided, could result in vehicle damage.1
IntroductionVehicle DescriptionAs with other PHEV, the Kia Optima PHEV uses the combination of a conventional gasolinepowered internal combustion engine and a High Voltage battery & electric motor to propelthe vehicle. This combination provides for improved gas mileage over a conventional Kia aswell 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 porton the left fender. This increases fuel efficiency and EV mode driving range. The HighVoltage battery is also automatically recharged while driving. This is accomplished throughthe engine and regenerative braking system that produces electricity while driving andbraking.2
Optima HEV IdentificationGeneral Vehicle DescriptionThe Kia Optima Plug-in Hybrid Electric Vehicle is built on the conventional Optima chassisand therefore the vehicle looks very similar to its conventional counterpart with a fewnotable exceptions. The safest method is to assume that any Optima you respond to is aPlug-in Hybrid Electric Vehicle until proven otherwise. Using the information provided inthis section, responders will be able to differentiate between the two.Identifying a Kia Optima Plug-in Hybrid Electric Vehicle“Eco plug-in” logo on trunk and side of vehicleThe 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.Electrocution RiskThe hybrid logo can become hidden after a crash due to damage to the vehicle. Always besure to use additional methods of identification before determining the vehicle is not ahybrid.3
Optima HEV IdentificationVIN numberThe 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.XXXXXXXDXXXXXXXXX8th digit4
Optima PHEV IdentificationEngine RoomAn “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 vehiclefrom 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 Identification6Charging PortThe charging port is located on the front left fender and it has one port for AC normalcharging.Note : The doors must be un-locked to open the charge port door.How to open the charging port1. Depress the brake pedal and apply theparking brake.2. Turn OFF all switches, move the shift leverto P (Park) and turn off the vehicle.3. Open the charging door by pressing it.Unlock charging door in emergencyIf the charging door does not open due tobattery discharge, open the hood and slghtlypull the emergency cable as shown left.The charging door will then open.
Optima PHEV IdentificationPlug-in Hybrid Electric Vehicle Instrument ClusterThe Plug-in Hybrid Electric Vehicle (PHEV) Instrument Cluster has specific features toidentify the Optima as a PHEV. Those features are circled below in red.Energy FlowCharge Status IndicatorThe High Voltage battery Charge Status Indicatoris visible from outside the vehicle. It is seenthrough the windshield at the center of the crashpad and is illuminated when the vehicle isplugged-in and charging.7
Optima PHEV Main Electric SystemsPower Electric SpecificationHybrid StarterGenerator (HSG)High-voltage batteryMotorTransmissionTypePermanent Magnet Synchronous MotorMax. Output HP(kW)67 (50)Max. Torque lb-ft(Nm)151 (205)InverterInput Voltage(V)200 310LDCMax. Output HP(kW)2.4 (1.8)TypeLithium-Ion PolymerRated Voltage (V)360Capacity (Ah) /Energy (kWh)27.2 / 9.8Cells96Power (kW)68MotorHPCUHigh VoltageBattery8
Optima PHEV Main Electric SystemsVehicle Components12V Auxiliary BatteryThe 12V auxiliary battery, located in the right hand side of the trunk, powers all of thevehicle’s standard electronic systems such as radio and air conditioner. Also, it powers theHPCU (Plug-in Hybrid Power Control Unit) which controls high voltage current to mainelectric systems like the motor.12V Auxiliary Battery9
Optima PHEV Main Electric SystemsMotorThe electric motor drives the vehicle and produces67HP (50 kW) and 151lb-ft (205 Nm) torque.Hybrid Power Control Unit (HPCU)The HPCU integrates an Inverter and LDC (Low PowerDC-DC Converter) in one housing. The inverterconverts DC to AC to supply electricity to the motor.It also converts AC to DC to charge the high voltagebattery. The LDC converts High Voltage AC electricityto Low Voltage DC to charge 12V auxiliary battery.High Voltage Battery SystemThe High Voltage battery stores electricity and suppliesit to the traction motor. It is a Lithium ion polymerbattery with specifications, 360V / 27.2Ah / 9.8 kWh. Itis located in the trunk of the Optima PHEV.Hybrid Starter Generator (HSG)The HSG restarts the engine in HEV mode and alsocharges the high voltage battery – the generator for Plug-in Hybridvehicle - while driving.10
Optima PHEV Main Electric SystemsOn-Board Charger (OBC)The OBC is the battery charging equipment thatconverts external AC to DC to charge the high voltagebattery.High Voltage Orange CablingThe High Voltage cabling is orange per SAE standard. Orange cables run under the floorof 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 compartmentidentify the vehicle as an electric vehicle.High Voltage Cables Never cut or disconnect the high voltage orange cabling and connectors without firstdisabling the system by removing the safety plug. Exposed cables or wires may be visible inside or outside the vehicle. Never touchthe wires, cables, connecters, or any electric components before disabling thesystem, to prevent injury or death due to electrical shock.Failure to follow these instructions can lead to death by electrical shock.11
Optima PHEV Main Electric Systems12Airbag system (SRS: Supplemental Restraint System)AirbagSeven airbags are installed in standard areas of the Optima Plug-in Hybrid Electric Vehicleso first responders can find them immediately. Before emergency procedure, make surethat the vehicle ignition is switched off, and disconnect the negative cable from the 12Vauxiliary battery to prevent accidental deployment of undeployed airbags.(1) Driver side front airbag(2) Passenger side frontairbag(3) Side airbag(4) Curtain airbag(5) Driver side knee airbag The actual airbags and seats in the vehicle may differ from the illustration.Seatbelt PretensionerThe Optima Plug-in Hybrid Electric Vehicle is equipped with driver side and front passengerside seatbelts with pretensioners. When the seatbelt pretensioners are activated in acollision, a loud noise may be heard and fine dust, which may appear to be smoke, may bevisible in the passenger compartment. These are normal operating conditions and are nothazardous. The seatbelt pretensioner assembly mechanisms may become hot duringactivation, and may need several minutes to cool after they have been activated.
Optima HEV Main Electric SystemsAirbag System Components1. Driver Airbag (DAB)8. Front Impact Sensor (FIS)2. Steering Wheel9. Curtain Airbag (CAB)3. Clock Spring10. Supplemental Restraint System Control4. Seatbelt Pretensioner (BPT)Module (SRSCM)5. Side Impact Sensor (SIS)11. Airbag Warning Lamp6. Side Airbag (SAB)12, 14. Emergency Fastening Device (EFD)7. Passenger Airbag (PAB)13, 15. Pressure Side Impact Sensor (PSIS)Undeployed AirbagsTo 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 the12V auxiliary battery, and wait 3 minutes or longer to allow the system todeactivate.Failure to follow any of these instructions may result in serious injury or death fromaccidental deployment of the airbag system.13
Emergency ProceduresInitial Response: Identify, Immobilize and DisableThe following procedures should be used whenever you are dealing with an Optima Plug-inHybrid Electric Vehicle at an emergency scene. All other operations should be consistentwith your department’s standard operating procedures or guides. Plug-in Hybrid ElectricVehicles damaged by a crash may have compromised High Voltage safety systems andpresent a potential High Voltage electrical shock hazard. Exercise caution and wearappropriate Personal Protective Equipment (PPE) safety gear, including High Voltage safetygloves and boots. Remove all metallic jewelry, including watches and rings.IdentifyWhen dealing with an Optima at an emergency scene, emergency responders shouldalways assume that it is a Plug-in Hybrid Electric Vehicle (PHEV) until it can be provenotherwise, using the identification clues outlined in this ERG. External logos will usually bethe 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 thehood and in the interior of the vehicle.14
Emergency Procedures15ImmobilizeThe next step is to immobilize the vehicle to prevent any accidental movement that canendanger response personnel and civilians alike. Although the Optima Plug-in HybridElectric Vehicle emits a virtual engine sound, if it is damaged from crash, there may beinstances where the vehicle appears to be shut off due to no engine sound.Whenthe "READY" lamp in the instrument cluster is illuminated, the vehicle canmove silently using the electric motor. Responders should approach the vehicle from thesides and stay away from the front or rear as they are potential paths of travel. Immobilizethe vehicle with the following procedure.Chock the wheels.Set the parking brake.Shift lever in park “P”.
Emergency Procedures16DisableAfter the vehicle is secured to prevent movement, the final step in the initial responseprocess 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 disablethe vehicle.I . Disabling the System – Smart Key System and “POWER” START/STOP Button1. Check the status of the READY light on theinstrument panel. If theREADY lightis illuminated, the vehicle is on.a) If the READY light is NOTilluminated, the vehicle is off. Do notpush the “POWER” START/STOPbutton as this may start the vehicle.“POWER” START/STOP Buttonb) To turn off the system, move the shift lever to Park "P" and press the POWER button.With brake pedal releasedPress POWERbuttonPOWER buttonLED colorVehicle conditionOffOffOne timeAmberElectrical accessories areoperational.Two timesReddish orangeThe warning lights can be checkedbefore the vehicle is started.Three timesOffOffWhile depressing the brake pedal while a shift lever is in the P (Park) positionPress POWERbuttonOne timePOWER buttonLED colorVehicle conditionOffOffOffReady to drive
Emergency Procedures2. If necessary, lower the windows, unlock the doors andopen the trunk as required, before disconnecting the12V battery. Once the 12V battery is disconnected,power controls will not operate.3. Before disconnecting 12V battery, move the Smart Keyat least 2 meters away from the vehicle to preventaccidental restart.Smart key4. Disconnect the negative (-) 12V battery cable, located in the trunk, to furtherprevent the risk of accidental restart.5. Remove the safety plug and disable the high voltage battery in the followingprocedure: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).d) Unfasten the lever (A).c) Unfasten the hook (A) to thedirection of arrow.e) Remove the safety plug (A).17
Emergency Procedures18II. Disabling the System – IG (Ignition) Fuse Removal1. Open the hood.2. Remove the engine room fuse boxcover.3. If necessary, lower the windows,unlock the doors and open the trunkas required, before disconnecting the12V battery. Once the 12V battery isdisconnected, power controls will notoperate.4. In the event the vehicle cannot beMulti FuseA Bdisabled using the “Power”START/STOP Button, pull the MultiFuse A and B along with IG3 Relayfrom the engine room fuse box. Ifthe IG Relay cannot be located,IG3Relaypull out all the fuses and relays inthe fuse box.5. Disconnect the negative (-) 12V battery cable, located in the trunk, to further preventthe risk of accidental restart.Before disconnecting the 12V battery (if needed), lower the windows, unlock the doorsand open the trunk as required. Once the 12V battery is disconnected, power controls willnot operate.
Emergency Procedures6. Remove the safety plug and disable the high voltage battery(Refer to No.5 procedure in page 17)If the above methods of disabling the system are unsuccessful, the vehicle is notsecured from accidental deployment of undeployed airbags and electric shock of highvoltage components.Electrocution Risk Before engaging in emergency response procedures, ensure the vehicle is disabledand wait 5 minutes to allow the capacitor in the high voltage system to dischargeto avoid electrocution. Exposed cables or wires may be visible inside or outside the vehicle. Never touchthe wires or cables before disabling the system, to prevent injury or death due toelectrical shock.Failure to follow these instructions can lead to death by electrocution.19
Emergency Procedures20Extraction OperationsThe Optima PHEV is an Eco-electric model (HEV/PHEV). Because of the high voltagecomponents contained therein, first responders should pay special attention when theyextract occupants in the car. Before extraction operations, the first responders should"Identify, Immobilize and Disable" the vehicle as discussed in sections on page 15-20.Vehicle StabilizationUse standard stabilization (cribbing) points,as shown on right. Always be sure toconnect to a structural member of thevehicle and avoid placing cribbing underhigh voltage cables, fuel lines and otherareas not normally considered acceptable.Extraction tools and procedureWhen responding to an incident involving an Optima Plug-in Hybrid Electric Vehicle, werecommend that the first responders follow their organization’s standard operatingprocedures for assessing and dealing with vehicle emergencies.When the first responders cut the vehicle, they should always pay special attention to airbagsystem, orange High Voltage cables and other High Voltage components due to the risk ofexplosion or electrocution from damaged partsLocation of ultra-high strength steelIn the image, high strength steel isused in the areas colored in blue andultra-high strength steel is used in thered colored areas. Depending on thetools used, ultra high strength steelcan be challenging or impossible tocut. If necessary, use a workaroundtechnique.Mild steelHigh strength steelUltra-high strength steel
Emergency Procedures21NO-CUT ZONESThe areas highlighted in yellow indicate “no-cut zones” that must not be cut duringemergency procedures due to high voltage, gas inflators and airbag hazards.Do not attempt to enter the vehicle by cutting through the "no-cut zones" identified in theimage below. Cutting through these zones can result in death by explosion orelectrocution.Airbag&Gas inflatorsAirbag12V BatterySupplemental Restraint System ControlModule (SRSCM)High Voltage Battery & CableGas inflatorsFuel systemRefrigerant gas pipe
Emergency Procedures22Vehicle FireAfter Initial Emergency Response Procedures have been applied, Firefighting Procedures maybegin. Kia recommends that each response team follow their own department’s standardoperating procedures for fighting vehicle fires in combination with the Optima PHEV specificdetails that are covered in this section.Firefighting OperationsIf the High Voltage battery is either in
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 .
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"Kia Vehicle" means a 2017 model year Kia Motor Vehicle manufactured by Kia Motors Corporation, 12-Heolleung-ro(231, Yangjae-dong), Seocho-gu, Seoul, 137-938, Korea. "Authorized Kia Dealer" means a person in the United States of America authorized by Kia Motors America, Inc. to service Kia Vehicles or perform repairs under the .
Please keep this manual with your Kia Vehicle. This manual should be presented to a Kia Dealer if warranty service is needed. This manual should remain with your Kia Vehicle if you sell it so future owners will have this information. Definitions As used in this manual (unless otherwise specifically stated): “Kia” means Kia Motors America, Inc., P.O.Box 52410 Irvine, CA 92619-2410, U.S.A .
Please keep this manual with your Kia Vehicle. This manual should be presented to a Kia Dealer if warranty service is needed. This manual should remain with your Kia Vehicle so if you sell it, the subsequent owner will have access to this information. Definitions As used in this manual (unless otherwise specifically stated); “Kia Canada” means Kia Canada Inc., 180 Foster Crescent .
warranty manual, Kia Motors America, Inc. (“Kia”) warrants that it will arrange for an Authorized EV Kia Dealer at locations of its choice to provide for the repair of your vehicle if it fails to function properly during normal use. An authorized EV Kia Dealer will remedy such failures to function properly at Kia’s expense, if
Kia Motors America, by the publication and dissemination of this material, does not create any warranties, either express or implied, to any Kia products. See your Kia retailer or kia.com for further details concerning Kia’s available limited warranties. 2013 Kia Motors America, Inc. Reproduction of the contents of this material without the .
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