Hyundai NEXO 2019 User manual

Hyundai Nexo & Tucson
Hydrogen Fuel Cell
Roadside Service Guide
Quality and Education Services
AAA Automotive
June 5, 2019
For the latest updates from AAA, visit:
AAAcampus.aaa.biz

Index
 Specications     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 qualied and trained personnel.
ThisRoadsideServiceQuickReferenceGuidewasdevelopedtohighlightsomemodel-specicinformation
and 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.
Theproceduresrecommendedanddescribedinthisguideareeectivemethodsofperforminglightservice
and 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 [email protected] or write us at:
AAA
Attention: TTR
1000AAADrive,MS33
Heathrow,FL32746
2

Hyundai Nexo & Tucson Fuel Cell Electric Vehicles
SPECIFICATIONS:
3
Specications
Nexo Tucson
Curb Weight (pounds) 4,116 4,150
Front Axle Weight 2,470 2,490
Rear Axle Weight 1,646 1,660
Drive Line Type Front-Wheel Drive (FWD) Front-Wheel Drive (FWD)
Transmission Type Automatic Automatic
Length 183.9inches 173.6inches
Width 73.2inches 71.6 inches
Wheelbase 109.8 inches 103.9inches
Height 64.6 inches 65.4 inches
Fuel / Propulsion Type Hydrogen / Electric Hydrogen / Electric
High-Voltage Battery 240 Volt DC Lithium-ion HV
Battery
180 Volt DC Lithium-ion HV
Battery
2019
Nexo - Fuel Cell
2014-2016
Tucson - Fuel Cell
*All images found in this document are courtesy of Hyundai Motor America.

4
HYDROGEN FUEL CELL ELECTRIC VEHICLE (FCEV) OVERVIEW
Inaneorttoproduceavehiclethatisfriendlytotheenvironment,HyundaidevelopedtheTucsonFCEV
and 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
Radiator
Electric
Motor
Fuel Cell
Stack
Hydrogen
Tanks
HV
Battery
Electrical
Current
Electrons
e movement of
electrons generates
electricity to power
the motor. Oxygen (O2)
Oxygen ows toward
the cathode, where it
combines with hydrogen
to produce water.
Hydrogen
(H2)
Hydrogen fuel
ows into the
anode. Anode
Negative
Electrode
PEM
Proton Exchange
Membrane
Cathode
Positive
Electrode
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.
Bothmodelsareeasilyidentiedwiththellportas
seen 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
alternativefuelvehiclesuntiltheycanbeconrmed
otherwise because badging can be removed, dam-
aged, or missing.
5
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
andcausesuocationtotheoccupants.Toprotectoc-
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 doors
Using the Mechanical Key:
6
Image A
Image B Image C
Image D
Nexo
1. 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
Tucson
1. 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
 3LiftgateUnlock
4 Panic Alarm
5 Remote Smart Parking Assist
6 Remote Start
Tucson Electronic Key Fob Functions
1 Door Lock
2 Door Unlock
 3TailgateUnlock
4 Panic Alarm
Releasing 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.
•IgnitionOn/MotorO:PresstheStart/Stop
switch 2 times without depressing the brake
pedal.
• To start the motor: Press the Start/Stop switch
while depressing the brake pedal.
7
Tucson FCEV
Nexo FCEV

e Tucson does not have an
interior button to open the
Tailgate.
8
TAILGATE RELEASE:
Electronic Key:
• Pressandholdbutton3shownin
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 FCEV
Nexo FCEV

9
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
steeringorsuspensioncomponent.Carefullyfollowtheloadingproceduresspeciedonthefollow-
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: Atanytimethevehicleismakingnoisesand/orventingvaporsthatcannotbeidentied,
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:
10
Eyebolt Locations
These vehicles are equipped with a loading eyebolt found inside the tool kit located under the rear cargo area
oorpanelthatscrewsintoareceiverinthepassengersidefrontandrearbumpers.
• 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 -Withyourfootothebrakepedal,pushthe
Start/Stop switch to select Accessory mode (the
motorwillbeo,theshiftpositioncanbechanged
to 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.
11
PARKING BRAKE:
Thesetwovehiclesareequippedwithdierenttypesofparkingbrakes.TheNexoisequippedwithanelctronic
parking brake while the Tucson is equipped with a foot brake near the driver’s side kick panel.
Tucson
Nexo

12
Observe all standard jacking precautions and place the jack in its proper location. Ensure
thevehicleisonrm,levelgroundandthatthewheelsarechocked.Asthejackcomes
in 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
inatorkitlocatedunderthecargoareaoorpanel.
CAUTION: Make sure to secure the vehicle using
wheel chocks prior to service.
NOTE:Onlyusetheinatorkitasalastresort.
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-Behindtherearseatbeneaththerearcargoareaoor
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
fromanapprovedfuelingstation.Aspecialllportinside
the 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.
-Ensurethevehicle’spoweristurnedo
- 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’sseatontheoor.
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
13
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
subtledierencestobeawareof.
• 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-
sureneededtofuelthevehicle.ThetwooptionsavailableareH35
(350bars)thatwillprovideahalftankoffuelandH70(700bars)
thatwillllthetanktoitsfull10,000lb.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. Removethenozzlefromthepumpandputitonthellport.
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. Pushthedesiredpressure(H35orH70).
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. Releasethelockonthenozzleandremovethenozzlefromthell
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.
14

15
JUMP-START PROCEDURES:
NOTE: Thesevehiclesareequippedwithtwodierenttypesof12vsystems.TheTucsonhasaconventional
12v battery located under the hood while the Nexo is equipped with a lithium-ion polymer type that is integrated
into the high-voltage battery.
Thefollowingjump-startingproceduresshouldbefollowedforeachspecicmodel:
• 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 2
Tucson:
The 12v battery is located in the rear cargo area beneath the
oorpanel.Followallnormaljump-startingprecautions.
• 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
12V
BATT
RESET