Hyundai SANTAFE Plug-in hybrid User manual

SANTAFE
Emergency Response Guide
Plug-in hybrid

Introduction ······························································································ 1
SANTAFE Hybrid Identification ·····································································
- Identifying a Hyundai Hybrid vehicle································································
SANTAFE Hybrid main systems ·····································································
- Vehicle Components Location ·········································································
- Airbag system (SRS : Supplemental Restraint System) ········································
Emergency procedures ···············································································
- Initial response: Identify, Immobilize and Disable ···············································
- Extraction Operations ···················································································
- Submersion ·································································································
- Vehicle Fire ·································································································
- High-Voltage Battery Damage and Fluid Leaks ··················································
Roadside Assistance
- Towing ·······································································································
- To Jump Start the Car ···················································································
Contents
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Document Purpose
The purpose of this document is to familiarize emergency responders and the towing/roadside
assistance industry with the proper methods to handle the Hyundai SANTAFE Hybrid in an
emergency situation. This guide offers a basic overview of key vehicle systems and provides
instructions for dealing with the different types of situations encountered by emergency
responders. The emergency response procedures for this vehicle are somewhat similar to a
conventional vehicle with additional information provided on dealing with the high-voltage
electrical system.
Vehicle Description
As with other Hybrids, the Hyundai SANTAFE Hybrid uses a conventional gasoline powered internal
combustion engine paired with a high-voltage electric motor to propel the vehicle. The high-
voltage electrical system is completely self-contained and does not need to be recharged by an
external power source such as a charging station through charging port. The high-voltage battery
is recharged while the vehicle is being driven. This is accomplished through the use of a generator
that produces electricity during driving and braking.
Introduction 1

SANTAFE Hybrid Identification 2
VIN number
The Vehicle Identification Number (VIN) as
shown in the below drawing is punched on
the floor under the passenger seat. The letter
2 in the 8th character of the VIN indicates
that it is a hybrid with 1.6 gasoline engine.
Engine Compartment and underside
The SANTAFE Hybrid has a plastic air cleaner
assembly with “HYBRID” clearly shown on it.
Additionally, there are orange colored high-
voltage electrical cables in the engine
compartment and underside.
XXXXXXX2XXXXXXX

SANTAFE Hybrid main systems
Vehicle Components Location
HPCU
Hybrid
Power Control Unit
Motor
When current flows through the coil.
It generates a
rotating magnetic field and generates motor torque.
H.V. Battery
Supplies
electric energy to traction motor and stores
generated electric energy .
H.V. Cable
The high
-voltage cabling is orange per the SAE standard.
On-Board Charger
The equipment that charges the high voltage battery using
the 110
-220V AC power.
3
•Never cut or disconnect the high voltage orange cabling and connectors without first disabling
the system by removing the safety plug.
•Exposed cables or wires may be visible inside or outside the vehicle. Never touch the wires,
cables, connecters, or any electric components before disabling the system, to prevent injury or
death due to electrical shock.
Failure to follow these instructions can lead to death by electrical shock.
Electrocution Risk!
High-Voltage Battery Assembly
High-Voltage Cable
Hybrid Motor
HPCU
Hybrid Starter Generator (HSG) On-Board Charger
12V Auxiliary Battery

SANTAFE Hybrid main systems 4
High-Voltage (HV) Battery
The High-Voltage battery is located below
the rear seat.
BMS(Battery Management System)
The BMS is located inside the High-Voltage
Battery assembly and measures several
parameters to maintain the optimal
performance of the High-Voltage Battery.
In addition, if a system fault occurs, the
BMS turns off the PRA to protect the
system.
PRA(Power Relay Assembly)
The PRA is located inside the High-Voltage
Battery Pack Assembly and controls the
high-voltage power circuit between the
High-Voltage Battery and the Hybrid Power
Control Unit.
12V Auxiliary Battery
The 12V auxiliary battery is located below
the luggage mat.
Vehicle Components
PRA
High-Voltage Battery
BMS

SANTAFE Hybrid main systems 5
Airbag system (SRS : Supplemental Restraint System)
1. Driver’s front airbag
2. Passenger’s front airbag
3. Front Seat Belt Pretensioner (FBPT)
4. Rear Seat Belt Pretensioner (RBPT)
5. Side Airbag (Driver, Passenger side)
6. Curtain Airbag (Driver, Passenger side)
7. Supplemental Restraint System Control
Module (SRSCM)
•Do not cut through any component.
•SRS components may remain powered and active for up to 3 minutes after the 12V electrical
system is shut off or disabled. Disconnect the battery negative cable and wait for at least 3
minutes before beginning work.
Failure to follow any of these instructions may result in serious injury or death from accidental
deployment of the airbag system.

Emergency procedures
Initial Response
The following procedures should be used whenever you are dealing with a SANTAFE Hybrid at an
emergency scene. All other operations should be consistent with your department’s standard
operating procedures or guides. Hybrid vehicles damaged by a crash may have compromised high
voltage safety systems and present a potential high voltage electrical shock hazard. Exercise
caution and wear appropriate personal protective equipment (PPE) safety gear, including high
voltage safety gloves and boots. Remove all metallic jewelry, including watches and rings.
Identify
When dealing with a SANTAFE at the scene of an accident, emergency responders should always
assume that it is a hybrid model until it can be proven otherwise using the identification features
outlined in this ERG. External badging will usually be the first clue but it can often be hidden by
damage caused in a crash. Always be sure to inspect multiple sides of the vehicle as well as using
the clues found under the hood and in the interior of the vehicle.
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Emergency procedures
Immobilize
The next step is to immobilize the vehicle to prevent any accidental movement that can endanger
the emergency response personnel and any crash victims. Since the SANTAFE Hybrid has the
ability to shut down the gasoline engine when it is not needed, there will be instances where the
vehicle appears to be off because of the absence of engine noise. When in its “ready” mode, the
vehicle can move almost silently using the electric motor alone. Responders should approach the
vehicle from the sides and stay away from the front or rear as they are both potential paths of
travel. Instructions for immobilizing the vehicle are shown below.
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Chock the Wheels
Engage Parking Brake
Push the shift button to park (P)

Emergency procedures
Disable
The final step in the initial response process, conducted after the vehicle is secured to prevent
movement, 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 disable the
vehicle.
Ⅰ. Disabling the system – Smart Key System and “POWER” START/STOP BUTTON
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1. Check the status of the READY light on
the instrument panel. If the READY light is
illuminated, the vehicle is on.
(Refer to page 5)
a) If the READY light is NOT illuminated,
the vehicle is off, Do not push the
“POWER” START/STOP button because
the vehicle may restart.
b) To turn off the system, put the shift
lever in the P (Park) position and press
the POWER button beside a shift lever.
“POWER” START/STOP Button
Pressing
POWER button Button Position Vehicle condition
OFF Off
One time ACC Electrical accessories are operational.
Two times ON The warning lights can be checked before
the vehicle is started.
Three times OFF Off
Depressing the brake pedal while a shift lever is in the P (Park)
position
Pressing
POWER button Button Position Vehicle condition
OFF Off
One time - Ready to drive
Without depressing the brake pedal