Hyundai Nexo & Tucson Hydrogen Fuel Cell

Roadside Service Guide

Quality and Education ServicesAAA Automotive

June 5, 2019

For the latest updates from AAA, visit:

AAAcampus.aaa.biz

Index

Specifications 3 Hydrogen Fuel Cell EV Overview 4 Identifying a Fuel Cell Electric Vehicle 5 Electronic Key/Mechanical Key 6 Start/Stop Switch 7 Electronic Key Not Detected 7 Hood Release 8 Tailgate Release 8 Car Carrier Loading 9 Towing Eyebolt Locations 10 Selecting Neutral 11 Tires and Jacking 12 High-voltage System 12 Fueling 13 Hydrogen Fuel Stations/Pump Ops 14 Jump-Start Procedures 15

Important Notice:

This publication should not be used while driving. The procedures in this publication should only be used by qualified and trained personnel.

ThisRoadsideServiceQuickReferenceGuidewasdevelopedtohighlightsomemodel-specificinformationand common procedures for servicing or towing these vehicles. It is not all-inclusive. For complete infor-mation: The applicable vehicle’s owner’s manual and the AAA/CAA Towing and Service Manual should be used in conjunction with this guide.

Theproceduresrecommendedanddescribedinthisguideareeffectivemethodsofperforminglightserviceand towing operations. Some of these procedures require the use of auxiliary equipment specially designed for the purpose. The auxiliary equipment should be used as recommended and whenever the trained operator deems it appropriate. It is important to read the various WARNINGS, CAUTIONS and NOTES in this manual in order to minimize the risk of personal injury to service personnel and/or customers and to avoid procedures which may damage the vehicle or render it unsafe. It is also important to understand that these warnings, cautions and notes are not exhaustive. Neither AAA nor the auto and towing equipment manufacturers could possibly know, evaluate and advise the reader of all conceivable methods of towing or evaluate individual situations. Accordingly, anyone who uses a towing procedure must be thoroughly convinced that neither personal safety nor vehicle safety will be jeopardized by the selected procedure.

AAA is not responsible for changes made by the manufacturers to the vehicles or their recommendations. Important changes in procedures and updates will be furnished to all manual users at AAACampus.aaa.biz.

To contact us regarding feedback on this publication, email us at TTR@national.aaa.com or write us at:

AAAAttention: TTR1000AAADrive,MS33Heathrow,FL32746

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Hyundai Nexo & Tucson Fuel Cell Electric Vehicles

SPECIFICATIONS:

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SpecificationsNexo Tucson

Curb Weight (pounds) 4,116 4,150Front Axle Weight 2,470 2,490Rear Axle Weight 1,646 1,660Drive Line Type Front-Wheel Drive (FWD) Front-Wheel Drive (FWD)Transmission Type Automatic AutomaticLength 183.9inches 173.6inchesWidth 73.2inches 71.6 inchesWheelbase 109.8 inches 103.9inchesHeight 64.6 inches 65.4 inchesFuel / Propulsion Type Hydrogen / Electric Hydrogen / ElectricHigh-Voltage Battery 240 Volt DC Lithium-ion HV

Battery180 Volt DC Lithium-ion HV Battery

2019Nexo - Fuel Cell

2014-2016Tucson - Fuel Cell

*All images found in this document are courtesy of Hyundai Motor America.

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HYDROGEN FUEL CELL ELECTRIC VEHICLE (FCEV) OVERVIEWInanefforttoproduceavehiclethatisfriendlytotheenvironment,HyundaidevelopedtheTucsonFCEVand has now transferred the technology to the Nexo FCEV. This general overview will assist you with a better understanding of how hydrogen fuel cell technology operates.

Fuel Type: Hydrogen Battery: DC Lithium-ion HV

How It Works: (Source: www.cafcp.org)This is a hydrogen fueled electric vehicle that does not re-quire it to be plugged in to recharge the battery. Instead, it is designed to function as outlined in the steps below. (Shown in the lower illustration.)1. Hydrogen fuel is stored in pressurized tanks and then

transferred to the fuel cell stack through high-pressure fuel lines.

2. Hydrogen enters the fuel cell stack where it contacts a negative electrode (anode) while oxygen from air enters the other side of the fuel cell stack where it contacts a positive electrode (cathode). These two electrodes are separated by a Proton Exchange Membrane (cata-lyst-coated membrane) where the electricity is created by hydrogen combining with oxygen to charge the high-voltage battery (process shown on the right). The high-voltage battery is the source of power for the elec-tric motor used to propel the vehicle during operation.

3. A power module then distributes the electricity through-out the vehicle, including the electric motor.

4. The electric motor turns the wheels by providing the torque needed to propel the vehicle.

The exhaust (by-product) created from this process that can be found coming from the tailpipe is water (H2O).

Source: California Fuel Cell Partnership

Source: California Fuel Cell Partnership

Electricity Generating Process

FCEV System Overview

Power Module

RadiatorElectricMotor

Fuel CellStack

HydrogenTanks

HVBattery

ElectricalCurrent

ElectronsThe movement of electrons generates electricity to power the motor. Oxygen (O2)

Oxygen flows toward the cathode, where it combines with hydrogen to produce water.

Hydrogen(H2)Hydrogen fuel flows into the anode. Anode

NegativeElectrode

PEMProton Exchange Membrane

CathodePositiveElectrode

Tailpipe Emissions are heat and water vapor

H2O

BADGING: These vehicles have unique badging around the exteri-or of the vehicle to help identify this vehicle from other models on the same platform.Grille Badge - The Hyundai “H” seen in image A has a blue highlight.

Fuel Door - Tucson models have a metallic ring with “Fuel Cell” engraved while the Nexo model does not. Bothmodelsareeasilyidentifiedwiththefillportasseen in image B.

Rear Badge - Both models are labeled with “Fuel Cell” on the passenger lower corner of the rear hatch. The Tucson model will also have a blue diamond with white writing labeled “Hydrogen” shown in image C.

Side Badging - Both vehicles have badging on the front fenders saying “Blue-Drive” as seen in image D.

NOTE: Treat all Tucson and Nexo vehicles as alternativefuelvehiclesuntiltheycanbeconfirmedotherwise because badging can be removed, dam-aged, or missing.

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IDENTIFYING A HYUNDAI HYDROGEN FUEL CELL ELECTRIC VEHICLE: These vehicles are fueled by hydrogen stored in pressurized tanks located in the rear of the vehicle and then propelled using power from a high-voltage battery.

Tucson Fuel CellNexo Fuel Cell

HYDROGEN SENSORS:

Hydrogen is an odorless gas that can displace oxygen andcausesuffocationtotheoccupants.Toprotectoc-cupants, hydrogen sensors seen in image E are required in these vehicles above the driver’s seat. An irritating alarm will sound when activated.

LABELING UNDER HOOD:

If the hood can be opened, the top of the hydrogen fuel cell has been clearly labeled as seen in image F.

Image A

Image B

Image C

Image D

Image F

Image E

DOOR LOCKS:Using the Electronic Key:Press button 2 seen in image A to unlock doorsUsing the Mechanical Key:

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Image A

Image B Image C

Image D

Nexo1. Press the end of

the handle closest to the front of the vehicle and pull out on the other end as shown in image B.

2. Using the mechani-cal key, remove the rubber plug found behind the door handle as shown in image D.

3. Insert the key and turn it clockwise as shown in image E.

Image E

Tucson1. Insert the mechan-

ical key into the key slot on the driver’s door han-dle and turn clock-wise as shown in image C.

2. Pull the handle to open the door.

ELECTRONIC/MECHANICAL KEY: Nexo Electronic Key Fob Functions 1 Door Lock 2 Door Unlock 3LiftgateUnlock 4 Panic Alarm 5 Remote Smart Parking Assist 6 Remote StartTucson Electronic Key Fob Functions 1 Door Lock 2 Door Unlock 3TailgateUnlock 4 Panic AlarmReleasing the Mechanical Key

Nexo Tucson

Press and hold button 1 and then slide the key out from the fob as seen in the images.

ELECTRONIC KEY NOT DETECTED:

This situation occurs when the electronic key has a low battery or there is interference from another type of signal near the electronic key.

Nexo - While depressing the brake pedal, press the Start/Stop switch with the electronic key as seen in the image.

Tucson - Place the electronic key in the recognition slot located on the front passenger corner inside the center console as seen in the image. With the electronic key in the slot, depress the brake pedal and attempt to start the vehicle. Once the key has been recognized, it can be removed from the slot.

Nexo

Tucson

START/STOP (IGNITION) SWITCH OPERATION: The electronic key must be in the vehicle. When detected, a message will display on the driver’s display panel.

•IgnitionOn/MotorOff:PresstheStart/Stop switch 2 times without depressing the brake pedal.• To start the motor: Press the Start/Stop switch while depressing the brake pedal.

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Tucson FCEVNexo FCEV

The Tucson does not have an interior button to open the

Tailgate.

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TAILGATE RELEASE:

Electronic Key:• Pressandholdbutton3shownin

the images till the tailgate begins to open.

Interior Button:• Press the interior release button

shown in the image till the tailgate begins to open.

Exterior Button:• Press and hold the exterior button

shown in the image till the tailgate begins to open.

NOTE: If the vehicle has a discharged 12v battery, power must be restored to access the cargo area unless the emer-gency release can be accessed inside.

HOOD RELEASE:

Interior Release:• Pull the release handle located on the

driver’s side kick panel.

Secondary Release:• Release the secondary release by

pulling up on the latch and lift the hood.

Tucson FCEVNexo FCEV

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CAR CARRIER LOADING AND TRANSPORTING:

Special Precautions:

• Car carrier equipment is the recommended method of towing and transporting this vehicle.

• When loading or winching, do not use hooks of any type on the lower control arms or any other steeringorsuspensioncomponent.Carefullyfollowtheloadingproceduresspecifiedonthefollow-ing pages.

• Only when the towing eyebolt is not available, use nylon tow straps around the front lower suspen-sion control arms. Ensure adequate clearance is maintained between the straps and the underside of the vehicle.

• Use only wheel strap tie-downs to secure this vehicle when transporting. The use of chains or hooks will damage under-vehicle components.

• In an emergency situation where the vehicle will not roll or must be moved for towing access, Go-Jaks or tire skates are recommended.

• Utilize ramping to reduce the approach angle and retain adequate ground clearance at both the front and rear of the vehicle.

WARNING: Atanytimethevehicleismakingnoisesand/orventingvaporsthatcannotbeidentified,move yourself and others to a safe distance from the vehicle and contact emergency responders. Maintain a safe distance until advised the vehicle is safe to transport. Image below shows venting locations that should raise suspicion for both the Tucson FCEV and the Nexo FCEV. These venting locations are in place to allow the hydrogen fuel tanks to vent when the internal pressure gets too high. Signs of this are a loud whistle and a pressurized vapor cloud at these locations.

NOTE: Avoid contact or damaging these areas by ensuring all tools and straps are away from these areas around the venting ports.

Car Carrier Loading Procedure:

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Eyebolt LocationsThese vehicles are equipped with a loading eyebolt found inside the tool kit located under the rear cargo area floorpanelthatscrewsintoareceiverinthepassengersidefrontandrearbumpers.• Remove the eyebolt receiver cover from the locations shown in the images below. • Turn the loading eyebolt clockwise into the receiver until secure. CAUTION: This towing point is not designed for recovery operations.NOTE: Secure the eyebolt receiver cover so it does not get lost or damaged during transport. We recommend placing it in the vehicle.

It is highly recommended to attach a second-ary backup nylon strap to the vehicle. This is a precaution in the event the eyebolt attachment should fail. Using a short nylon strap, wrap the lower control arm and attach the other end to the winch line hook. This strap will remain slack and will only be utilized as a securing device if the eyebolt attachment fails.

Secondary Safety Strap:

Tucson FCEVNexo FCEV

In the event Neutral cannot be selected or a failure with the parking brake mechanism causes the wheels not to roll, wheel dollies such as “GoJaks” or tire skates should be used on the non-rolling wheels to assist with load-ing the vehicle. Care must be taken when installing tire skates or GoJaks due to the limited clearance around the wheels and between the vehicle and the ground.

Wheel Dollies/Tire Skates:

SELECTING NEUTRAL:

If the vehicle can be shifted normally:Nexo - Depress the brake pedal and select Neutral.Tucson - Depress the brake pedal and slide the shift lever to the Neutral position.If the vehicle has power, but will not start:Nexo -Withyourfootoffthebrakepedal,pushtheStart/Stop switch to select Accessory mode (the motorwillbeoff,theshiftpositioncanbechangedto Neutral).Tucson - Depress the brake pedal, remove the plastic cover from the override and press the shift release using a small screwdriver as seen in the image.

Car Carrier Loading Procedures:

• Before loading, if possible, place the vehicle in Neutral with the parking brake released. Only load the vehicle onto the car carrier enough to safely transport the vehicle. Stop loading when the winch line begins to pull the vehicle downward. To prevent excessive downward pull, keep the leading edge of the vehicle at least 2 feet from the winch drum (this will vary based on the towing equipment being used).

• When the vehicle is in its loaded position on the car carrier with the bed still in the deployed position, secure the vehicle to prevent it from rolling by chocking the wheels and attaching one wheel strap to the wheel closest to you. Continue to secure the vehicle until all four wheels are secure.

• Clearance around the wheel may be limited and careful routing of straps is needed to avoid contacting brake lines and wires, especially behind the front wheels. Careful routing of the straps is also important to avoid contact with the painted surfaces of the vehicle.

• Once the bed is in its transport position and the vehicle is secured to the bed with four wheel strap tie-downs, place the vehicle into Park to help secure the vehicle. Also ensure the vehicle is OFF and the elec-tronic key is removed from the vehicle.

• After securing, slacken the winch line slightly to prevent any downward pull on the vehicle during transport.

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PARKING BRAKE:Thesetwovehiclesareequippedwithdifferenttypesofparkingbrakes.TheNexoisequippedwithanelctronicparking brake while the Tucson is equipped with a foot brake near the driver’s side kick panel.

Tucson

Nexo

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Observe all standard jacking precautions and place the jack in its proper location. Ensure thevehicleisonfirm,levelgroundandthatthewheelsarechocked.Asthejackcomesin contact with the vehicle body, ensure that it is not contacting any high-voltage or other components that may be damaged. Continue lifting to raise the vehicle just enough to perform the service needed.

TIRES AND JACKING:

Neither vehicle comes equipped with a conven-tional spare tire. Instead, both are equipped with an inflatorkitlocatedunderthecargoareafloorpanel.

CAUTION: Make sure to secure the vehicle using wheel chocks prior to service.

NOTE:Onlyusetheinflatorkitasalastresort.

Tire Pressure:Proper tire pressure can be found on the tire placard located on the driver’s side door pillar. Tire pressure settings are also listed in the vehicle owner’s manual.

Jacking Locations

Wheel Torque:Nexo - 79-94 lb. ft. Tucson - 65-79 lb. ft.

HIGH-VOLTAGE SYSTEM:

LOCATION:

Nexo-Behindtherearseatbeneaththerearcargoareafloor

Tucson - Under the vehicle in the center.

Battery Type: Lithium-ion HV battery for both models

Battery Voltage: 240 volts (Nexo) / 206 volts (Tucson)

CAUTION: Avoid all contact with high-voltage orange loom.

Nexo Tucson

High Voltage Battery

Hydrogen Storage System

FUELING:These vehicles do not operate on conventional gasoline or diesel. Instead, they are fueled with compressed hydrogen fromanapprovedfuelingstation.Aspecialfillportinsidethe fuel door is used to add hydrogen to the storage cylin-ders. Roadside fuel delivery is not available at this time. In the event an FCEV is found to be out of fuel, the vehicle will need to be towed to the nearest approved hydrogen fueling station and unloaded from the tow vehicle to be refueled.NOTE: Do not attempt to refuel this vehicle while it is still loaded on the tow vehicle. Once the vehicle has been unloaded from the tow vehicle, the following can be done to assist the owner in refueling.-Ensurethevehicle’spoweristurnedoff- Open the fuel door.

Nexo - Press the fuel door button on the left side of the dash. If the fuel door will not open when the button inside is pressed, a fuel door override is provided inside the rear cargo area on the driver’s side. It is a clearly labeled black T-handle that is easily accessible.Tucson - Pull the release handle located left of the driv-er’sseatonthefloor.

FUEL CYLINDERS:The fuel cylinders in these vehicles are high-pressure cyl-inders designed to hold pressures up to 10,000 psi. To help protect the cylinders from becoming over pressurized, there is a Pressure Relief Valve (PRV) built into the system that directs the pressure down to the ground under the vehicle when it is activated. In the event this occurs, make sure to move a safe distance from the vehicle and call emergency services.

Nexo

Tucson

Nexo

Tucson

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High Voltage Battery

Hydrogen Storage System

HYDROGEN FUEL STATIONS:Hydrogen fueled vehicles are able to be fueled much the same way as a conventional gasoline or diesel vehicle. However, there are some subtledifferencestobeawareof.• A pin number is required to operate the pump. This pin number can

be obtained once the operator has completed a short instructional video played at the pump demonstrating how to safely fuel the vehicle. Once a pin number has been provided, make sure to record the pin for future use.

• Instead of selecting an octane rating, the operator selects the pres-sureneededtofuelthevehicle.ThetwooptionsavailableareH35(350bars)thatwillprovideahalftankoffuelandH70(700bars)thatwillfillthetanktoitsfull10,000lb.capacity.NOTE: Not all pumps are equipped with both options.

Fueling Procedures:1. Ensure the vehicle is in Park, park brake is set, vehicle OFF, and

then open the fuel door and remove the dust cap.2. Swipe the method of payment (credit card).3. Pump will ask for a pin #. This pin is required to operate the pump.

If you have one, select YES and enter the pin #. If you do not, select NO and watch the short instructional video to get a pin #. Keep this pin # to use in the future.

4. Removethenozzlefromthepumpandputitonthefillport.5. Lock the nozzle by squeezing the handle till the lock on the handle

engages. Pull gently on the nozzle to ensure it locked.6. Lift the lever on the pump.7. Pushthedesiredpressure(H35orH70).8. The pump will perform a test on the seal of the nozzle to ensure it

can safely dispense and then automatically begin pumping.NOTE: Pump operation can be stopped at any time by lowering the lever on the pump.

9. When pumping is complete, lower the lever on the pump.10. Releasethelockonthenozzleandremovethenozzlefromthefill

port after releasing the lock.NOTE: The nozzle may stick because it is frozen to the port during transfer. Let it sit a few seconds to thaw. Do not use exces-sive force to separate.

11. Hang the nozzle up, replace the dust cap and close the fuel door.

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JUMP-START PROCEDURES:NOTE: Thesevehiclesareequippedwithtwodifferenttypesof12vsystems.TheTucsonhasaconventional12v battery located under the hood while the Nexo is equipped with a lithium-ion polymer type that is integrated into the high-voltage battery.

Thefollowingjump-startingproceduresshouldbefollowedforeachspecificmodel:• Follow all normal jump-starting precautions as outlined in other AAA/CAA publications.• Ensure that all electrical accessories and the ignition are turned OFF and the electronic key is removed

from the vehicle and stored at least 15 feet away from the vehicle before connecting jump cables or a jump box.

These best practices have been researched to promote safe damage-free practices.For the latest updates from AAA, visit: AAAcampus.aaa.biz

Nexo:This vehicle has a special procedure for a discharged 12v system.• Locate the “12V BATT RESET” button (Figure Nexo

1) located on the dash near the driver’s left knee.• Press the “12V BATT RESET” button until the instru-

ment cluster illuminates.• Depress the brake pedal and press the START/STOP

button.NOTE: If the “12V BATT RESET” does not respond, attempt to jump-start using the following procedure.1. Connect to the (+) positive terminal under the hood

on the passenger’s side (Figure Nexo 2).2. Connect the (-) ground to a clean non-painted chas-

sis ground.3. Press the “12V BATT RESET” button until the

instrument cluster illuminates.4. Depress the brake pedal and press the START/

STOP button.

Nexo 1

Nexo 2Tucson:The 12v battery is located in the rear cargo area beneath the floorpanel.Followallnormaljump-startingprecautions.

• Connect the (+) positive cable to the (+) positive terminal of the battery (Figure Tucson).

• Connect the (-) ground to a good, conductive non-painted or insulated surface.

• Depress the brake pedal and press the POWER button.

• Once running, allow the battery to charge a few minutes before disconnecting the jump leads.

• Disconnect jump leads in the reverse order Tucson

12VBATT

RESET