2014 Kia Optima Hybrid Service & Repair Manual

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General Information Safety Precaution Since hybrid vehicles contain a high voltage battery, if the high voltage system or vehicles are handled incorrectly, this might lead to a serious accidents like electric shock and electric leakage. • 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”) • The responsible worker keeps the removed safety plug to prevent the plug from being connected by mistake. • Do not keep any metal objects (watch, ring etc.) while working on the high voltage system, which it can cause serious accidents like electric shock. • Before beginning work on the high voltage system, the worker should wear personal protective equipment to prevent safety accidents. (Refer to “Personal Protective Equipment”) • Never allow workers who are not wear personal protective equipment to touch the high voltage system. High voltage components should be covered with an insulation sheet to prevent safety accidents. • Use insulation tools when working on the high voltage system. • Put the removed high voltage components on the insulation mat. • 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: 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), Power Cable, Electric Compressor etc. Use Mega Ohm Tester when measuring insulation resistance of the high voltage system. Specification : High Impendance Digital Volt / Ohm Meter (DVOM) "Category 3" Leads and Meter rated to 1,000 voltage. Inform of danger of high voltage by putting the “high voltage caution” on the vehicle as image below. Page 1 sur 24 2014-10-10 https://www.kiatechinfo.com/viewer/print_pop.aspx?printtype=sprint&vehicletype=Pass...

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Personal Protective Equipment Name Illustration Description Insulation glove Used when inspecting or working on the high voltage components [Insulation performance : 1000V / 300A or above] Page 3 sur 24 2014-10-10 https://www.kiatechinfo.com/viewer/print_pop.aspx?printtype=sprint&vehicletype=Pass...

Insulation shoes Used when inspecting or working on the high voltage components Insulation clothes Insulation helmet Safety glasses Used in the case below • During Removal & installation or inspection of the high voltage battery terminals or wiring, which spark might happen. • During working on the high voltage battery pack assembly. Face shield Insulation mat Putting the removed high voltage components on the insulation mat to prevent safety accidents. Insulation sheet Covering the high voltage components with insulation sheet to prevent people who don’t wear the personal protective equipment from safety accidents. Page 4 sur 24 2014-10-10 https://www.kiatechinfo.com/viewer/print_pop.aspx?printtype=sprint&vehicletype=Pass...

General Information Be sure to follow instructions below when repairing the high voltage cable. • Check the voltage of the high voltage connector, terminal or busbar before repairing. Below 30V: High voltage circuit properly shut More than 30V: High voltage circuit faulty • Be careful not to short circuit between positive (+) and negative (-) terminals. • Insulate the high voltage connector or terminal with an insulation tape after disconnecting. • Tighten the high voltage terminal with the specified torque. The high voltage battery must be always handled horizontally during repairing or storage. Otherwise, there may be decline in battery performance or its life may be shortened. Exposing the high voltage battery to intense heat may cause deterioration. Do not bake over 70°C (158°F) / 30 min or 80°C (176°F) / 20 min when painting. Hybrid Vehicle Refrigerant Recovery / Charging Precautions • Since the electric compressor uses high-voltage, you should use POE oil which have high Volumetric Resistivity. • Do not use the same A/C recovery / charging station as conventional belt-driven compressors. If the POE oil of the system gets mixed with PAG oil, then dielectric breakdown due to decreased volumetric Resistivity can occur and inoperative A/C compressor may result, A/C compressor may not work. High Voltage Shut-off Procedures 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. • High voltage components: 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), Power Cable, Electric Compressor etc. 1. Turn the ignition switch OFF and disconnect the auxiliary 12V battery negative (-) terminal. 2. Remove the safety plug. (1) Remove the safety plug cover (A). (2) Unfasten the hook (A) and then remove the safety plug (C) by pulling the lever (B) to the direction of arrow. Page 5 sur 24 2014-10-10 https://www.kiatechinfo.com/viewer/print_pop.aspx?printtype=sprint&vehicletype=Pass...

3. Wait for more than 5 minutes so that the capacitor in the high voltage system can be fully discharged. 4. Measure the voltage between the inverter terminals to check that the capacitor in the inverter is discharged completely (1) Remove air cleaner assembly and air duct.(Refer to Engine Mechanical System – “Air Cleaner”) (2) Disconnect the inverter power cable (A). Disconnect the inverter power cable as the procedures below. Page 6 sur 24 2014-10-10 https://www.kiatechinfo.com/viewer/print_pop.aspx?printtype=sprint&vehicletype=Pass...

General Information (3) Measure the voltage between the inverter (+) terminal and the inverter (-) terminal. Less than 30V :High voltage circuit properly shut More than 30V :Faulty on high voltage circuit If measured more than 30V, check if the safety plug is removed completely.If measured more than 30V despite the safety plug is removed, it can be serious problems on the high voltage circuit. In this case, check DTC and never touch on the high voltage system. Identification Number Locations Page 7 sur 24 2014-10-10 https://www.kiatechinfo.com/viewer/print_pop.aspx?printtype=sprint&vehicletype=Pass...

2014 Kia Optima Hybrid Service & Repair Manual

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