2021 Hyundai NEXO (FE) 113KW Service & Repair Manual

NEXO(FE) > 2021 > 113KW > General Information - General Safety Information and Caution The NEXO Hydrogen Fuel Cell vehicle operates on approximately 180 - 400 volts DC and uses high pressure hydrogen gas as a fuel source. Be sure to follow safety instructions below. Failure to follow safety instructions may result in serious injury or electrocution. [Safety precaution for Hydrogen system] Hydrogen Gas Features Hydrogen is a unique gaseous element that possesses the lowest molecular weight of any gas. It is colorless, odorless, tasteless, non-corrosive, flammable and highly volatile. Hydrogen is a combustible fuel. Therefore, some precautions must be taken when performing service on a hydrogen fuel cell vehicle. However, it is no more dangerous and it is rather less dangerous than other commonly used fuels in some respects. Hydrogen has much lower density which gives it a comparative advantage from a safety point of view. Owing to this, hydrogen gas tends not to mix with air and disperses upwards in the air. This means that the concentration levels of hydrogen necessary for ignition or detonation are unlikely to be achieved. Hydrogen is a very small molecule with low viscosity, and therefore prone to leakage. Proper ventilation and the use of hydrogen detection sensors can help to mitigate some of the hazards associated with gaseous hydrogen. The followings are properties of gaseous hydrogen. • It has the lowest molecular weight, and has the smallest molecules of any elements. • It has the lowest density and the highest buoyancy of any element. • It can cause brittleness in some materials, including metals (but materials chosen for hydrogen applications are not susceptible to brittleness). • It is colorless, odorless and tasteless. • It burns invisibly and without smoke. • It has the lowest ignition energy of any fuel (less than one-tenth that of other fuels). • It has a wide flammability concentration range of 4% to 75% When servicing the hydrogen storage and supply system, pay attention to the following items. • Clean all work shop and surrounding areas before removing the part. • Place removed parts on a clean cover and surface. • Use lint-free cloths only. • Carefully cover or seal opened parts with a tape if repairs cannot be carried out immediately. • Install clean components only. • Defined regulations for hydrogen system service may vary with countries. Therefore all service and maintenance instructions are based on local country requirements safety regulations. • The NEXO Hydrogen Fuel Cell vehicle must be repaired in authorized workshops that are equipped with proper ventilation and a hydrogen detection system. • There must be no ignition sources around the vehicle. For example, any exposed flames, sparks, electrostatic discharge, or hot surfaces that could cause hydrogen gas to ignite must be kept away from the vehicle.

When servicing parts related to the hydrogen supply system, adhere to the following requirements: 1) When leaking the hydrogen gas, make sure there is no source of ignition near the leakage path. 2) Always empty the hydrogen tank according to the following safety guideline. 3) As the system is applied with pressure, gas leak may lead to dangerous situation and injury. 4) The hydrogen tank is fueled with the high pressure hydrogen gas. Make sure to empty the hydrogen tank before removing it. 5) Do not disassemble the hydrogen tank and solenoid valve even when the tank is empty. Random disassembling of the hydrogen tank may cause fire and explosion. 6) Clear the combustible substances around the vehicle before the inspection. 7) Completely remove the remaining fuel gas in the fuel line before inspecting the hydrogen storage system. (Refer to Hydrogen Storage System - Repair procedures - "Residual fuel pressure release procedure") 8) When removing the hydrogen storage and supply system, do not work with the compressed air as much as possible. 9) Before removing the hydrogen system, cover the connection part with the cloth. Then, carefully remove the component. 10) When inspecting the component related to the hydrogen storage system, make sure to use hand tools in order to prevent any fire due to spark from the electrically driven tools. • Caution labels are attached to the hydrogen storage system components. The hydrogen storage system is composed of three cylinders which are filled with Hydrogen gas. The hydrogen tank is made of the high density plastic material with excellent gas barrier properties against hydrogen gas and carbon fiber composite material which is capable of withstanding the high pressure. Each tank contains flammable gas under high pressure. Serious injury or death can result from improper installation, lack of maintenance or overfilling. Do not attempt to remove the hydrogen storage tanks or any of its fittings from this vehicle. They may contain residual gases under pressure, which could cause fire or explosion. • Removal and disposal shall only be done by a qualified technician. Installation of this cylinder must be done in accordance with the manufacturer’s instruction and local regulation. • Hydrogen storage components : Hydrogen Management Unit (HMU), Hydrogen Sensor, Hydrogen Tank, Hydrogen Tank Solenoid Valve Assembly, Hydrogen Tank Purge Valve, Filling Receptacle Assembly, High Pressure Regulator, Check Valve, etc [Safety precaution for High voltage system] • Warning labels for high voltage are attached to the high voltage components. The color of the high voltage cables and connectors are orange. Do not touch any of these high voltage components, cables, and connectors without proper Personal Protection Equipment (PPE). • High voltage components : Fuel cell stack assembly, Fuel cell Control Unit (FCU), Air Blower, COD Heater, High voltage Junction Box, High Voltage Battery Pack Assembly, Power Relay Assembly (PRA), BMS ECU, Drive Motor, Electric A/C Compressor, High voltage DC/DC Converter (HDC), Low DC/DC Converter (LDC), Power Cable, etc.

• Use Mega Ohm Tester when measuring insulation resistance of the high voltage system. Specification : High impedance Digital Volt / Ohm Meter Leads and Meter rated to 1,000 voltage. • For your safety when servicing the Fuel Cell Electric Vehicle (FCEV): – Wear Personal Protection Equipment (Insulation Gloves and Safety Glasses) – Do not carry any metallic object (watch, ring etc.) which can cause short circuit. – Use insulated tools • Before wearing the protective gear, make sure that they are not torn or broken and free of moisture. Insulating Gloves Safety Glasses • Before repair work for any Fuel cell, High voltage, Hydrogen system component, be sure to perform the procedures as below. 1. Start the fuel cell system by pressing the power button. 2. Check the hydrogen gas leak detection lamp on the cluster. 3. Shut off the high voltage circuit shown in the procedures below. (Refer to "High Voltage Shut off Procedure" for more detailed procedures.) (1) Turn the fuel cell system power button off and then wait for at least 3 minutes. Disconnect the auxiliary 12V battery negative (-) connector (A). (2) Remove the safety plug (B). • Starting the fuel cell system with the safety plug removed may damage the fuel cell control system.

(3) Wait for more than 5 minutes so that the capacitor in the high voltage system can be naturally discharged. (4) Measure the voltage between the inverter positive and negative power cable terminals to check for inverter discharge. (1) Remove the high voltage junction box cover. (2) Measure the voltage between the inverter positive and negative bus bar terminals to check for capacity discharge. Below 30V : High voltage circuit properly shut More than 30V : High voltage circuit faulty • Re-check by removing the safety plug, if the voltage is measured over 30V. • If the voltage is over 30V even though the safety plug is removed, a serious problem will occur in the high voltage circuit. In this case, perform the DTC diagnosis and do not do any work associated with the high voltage system. (5) Remove the high voltage junction box cover. And measure the voltage between the positive and negative bus bar terminals to check the shut off of the fuel cell. Below 5V : Fuel cell system circuit properly shut More than 5V : Fuel cell system circuit faulty • Re-measure the voltage after 10 minutes, if the voltage is measured over 5V. • If the voltage is over 5V again, a serious problem will occur in the fuel cell system circuit. • In this case, perform the DTC diagnosis and do not do any work associated with the fuel cell system. • Attach the 'High Voltage Caution Car Topper' to the vehicle roof to inform other people of the danger of high voltage.

Be sure to follow instructions below when repairing the high voltage cable. • Check the voltage of the high voltage connector, terminal or bus bar 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, battery performance may decline or its life may shorten. • 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. Fuel Cell Electric Vehicle Refrigerant Recovery / Charging Precautions • Since the electric compressor uses high-voltage, you should use POE oil which has high Volumetric Resistivity. • Do not use the same A/C recovery / charging equipment 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 deteriorate A/C compressor performance or it may not work. Air Processing System, Thermal Management System and Fuel Processing System Repairing Precautions • Air Ducts and Hoses - To protect fuel cell system, block the open end of the air ducts and hoses using the plugs (09356-4W170). • Coolant Hoses and Pipes - To prevent technicians coming in contact with coolant and protect electrical systems, block the open end of the coolant hoses and pipes using the plugs (09356-4W170). Stack Cooling System

Motor Cooling System • Fuel, Air and Coolant Paths of Fuel Cell System Components - To protect the fuel cell system, seal the hydrogen, air or coolant path with the cap (09356-5M240) or tape after removing the fuel cell system component.

NEXO(FE) > 2021 > 113KW > General Information - Important Safety Notice Proper service methods and repair procedures are essential for safe, reliable operation of all motor vehicles as well as personal safety of the operator. The service procedures and descriptions in this shop manual provide general directions for a service and repair. Procedure, techniques, tools, and parts for service including the skill of the technician vary. It is impossible to provide advice or caution as to each case in this manual. Accordingly, anyone who intends to use a replacement part, service procedure, or tool, which is not recommended by the vehicle manufacturer, must first assure thoroughly that neither their personal safety nor the safe operation of the vehicle will be jeopardized by the replacement part, service procedure, or tool they chose to use. • Reminds you to be especially careful in those areas where carelessness will cause death or serious injury. • Reminds you to be especially careful in those areas where carelessness may cause death or serious injury. • Reminds you to be especially careful in those areas where carelessness may cause personal injury. • Gives you information that will prevent you from making errors that could damage the vehicle. • Gives you added information that will help you complete a particular procedure. The following list contains some general WARNINGS that you should follow while working on a vehicle. • Always wear safety glasses for eye protection. • Use safety stands whenever a procedure requires you to be under the vehicle. • Make sure that the ignition switch is always in the OFF position, unless otherwise required by the procedure. • Set the parking brake when working on the vehicle. • Place support against the front and rear surfaces of the tires to help prevent the vehicle from moving. • Do not smoke while working on a vehicle. • To avoid injury, always remove rings, watches, loose hanging jewelry, and loose clothing before beginning to work on a vehicle. • When it is necessary to work under the hood, keep hands and other objects clear of the electric fanblades! Care should betaken be taken to ensure that the electric fan motor is completely disconnected when working under the hood.

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2021 Hyundai NEXO (FE) 113KW Service & Repair Manual

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