22-01-080H

GROUP
CAMPAIGN
Technical Service Bulletin
SUBJECT:
DATE
OCTOBER 2022
NUMBER
22-01-080H
MODEL(S)
NEXO (FE)
HMU UPDATE & PRESSURE RELIEF VALVE (PRV) REPLACEMENT
(SERVICE CAMPAIGN T9A)
 IMPORTANT
*** Dealer Stock and Retail Vehicles ***
Dealers must perform this campaign on all affected vehicles prior to customer retail delivery
and whenever an affected vehicle is in the shop for any maintenance or repair.
Access the Vehicle Information Screen (VIS) via WEBDCS to identify open campaigns.
Description: Some NEXO (FE) vehicles may exhibit charging interruptions during hydrogen charging
due to sensitive leak detection logic diagnostic conditions. This bulletin outlines the procedure to
update the HMU controller software and replace the PRV (Pressure Relief Valve).
STUI
This TSB includes STUI pictures as a requirement. Where indicated, please include a copy
of the RO or last 6 digits of the VIN and date of repair on a piece of paper. Ensure the VIN
and date of repair are clearly visible. Finally, please ensure all captured pictures are
completed according to the steps in this TSB and uploaded to STUI. All claims submitted
that have illegible, incomplete, missing, or incorrect picture(s) are subject to debit.
Applicable Vehicles: Certain 2019MY ~ 2022MY NEXO (FE) vehicles.
NOTICE
•
The TSB repair procedure MUST be performed at an authorized Hyundai NEXO fuel cell
vehicle dealer and by a Hyundai Expert (or above level) technician who has successfully
completed the Fuel Cell Electric Vehicle Training Instructor Led Training course
(SVCHFCEVTRAIN222_1097).
•
Refer to OSHA standard 1910.137 - Electrical Protective Equipment for PPE inspection and
testing requirements and the NEXO shop manual for PPE usage.
Circulate To: General Manager, Service Manager, Parts Manager, Warranty Manager, Service
Advisors, Technicians, Body Shop Manager, Fleet Repair
HMU UPDATE & PRESSURE RELIEF VALVE (PRV) REPLACEMENT (SERVICE CAMPAIGN T9A)
SUBJECT:
Parts Information:
PART
NUMBER
REMARKS
Pressure Relief Valve (PRV)
35904M5000QQH
1 Each
Sealant Threebond 1211
2145133T02QQH
PART NAME
Hydrogen Leak Detector
IMAGE
No Image
SNOOP RC Leak check fluid
1 tube can be used for about 100
vehicles
None
Part of Dealer Nexo SST Kit
None
Only need if leak detector fails
Warranty Information:
OP CODE
OPERATION & CONDITIONS
20D050R2 If - Hydrogen tank pressure is 1,100 PSI or
less and fuel supply lines are depressurized
(i.e., performed but claimed via separate
repair or campaign TSB).
Then – HMU UPGRADE & PRV
REPLACEMENT
OP
TIME
SUBLET
1.1 M/H
$0.29
20D050R3 If - Hydrogen tank pressure is 1,100 PSI or
less (i.e. customer drove in with low fuel) and
fuel supply lines need depressurization.
Then – DEPRESSURIZE FUEL SUPPLY
LINES AND PERFORM HMU UPGRADE
AND PRV REPLACEMENT
1.5 M/H
$150.29
20D050R4 If - Hydrogen tank pressure is 1,101 PSI or
more
Then – DEFUEL (VENT) TANKS TO 1,100
PSI OR LESS, DEPRESSURIZE FUEL
SUPPLY LINES AND PERFORM HMU
UPGRADE AND PRV REPLACEMENT
2.3 M/H
$150.29
CAUSAL NATURE CAUSE
PART
CODE CODE
35904M5000
QQH
B21
ZZ1
NOTE 1: Submit claim on Campaign Claim Entry Screen
NOTE 2: Op Code 20D050R2 accounts for the related defueling (venting), depressurizing fuel supply
lines, and refueling of vehicle costs being covered via a separate repair claim outside of this TSB.
NOTE 3: Op Codes 20D050R3 and 20D050R4 include $150.00 for transportation of the vehicle to the
fueling station ($50) and fuel to refuel vehicle ($100).
Please DO NOT submit a separate claim with duplicate labor or sublet. If defueling/refueling is
required for overlapping repairs/campaigns, submit the applicable labor operation for
defueling/refueling on ONLY ONE of the claims.
NOTE 4: All Op Codes include $0.29 for Threebond Sealant per vehicle.
TSB #: 22-01-080H
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HMU UPDATE & PRESSURE RELIEF VALVE (PRV) REPLACEMENT (SERVICE CAMPAIGN T9A)
NOTE 5: If a part that is not covered by this campaign needs replacement while performing this
campaign, and the affected part is still under warranty, submit a separate claim using the same repair
order. If the part is out of warranty, submit a prior approval request for goodwill consideration prior to
the work.
NOTE 6: The incident parts are subject to callback through the normal Warranty Technical Center
(WTC) parts return process. Claim is subject to debit if the part is requested and not returned.
NOTE 7: Claim must include STUI pictures that are clearly visible along with a piece of paper
displaying the last 6 digits of the VIN and date of the procedure. Claims submitted with illegible,
incomplete, missing or incorrect pictures are subject to debit.
TSB #: 22-01-080H
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HMU UPDATE & PRESSURE RELIEF VALVE (PRV) REPLACEMENT (SERVICE CAMPAIGN T9A)
SUBJECT:
HMU Update & Pressure Relief Valve (PRV) Replacement
Perform HMU Update
Defuel tanks to 1,100 PSI (7.58 Mpa)*
Is tank pressure
less than or equal 1,100
PSI (7.58 MPa)
NO
YES
Depressurize fuel supply lines
Depressurize fuel supply lines
Replace Pressure Relief Valve (PRV).
Replace Pressure Relief Valve (PRV)
Repair leak**
NO PASS
Leak check
PASS
Refuel hydrogen tanks
Repair leak**
Depressurize fuel supply lines
Defuel tanks to 1,100 PSI (7.58 Mpa)*
NO PASS
Leak check
PASS
Reinstall
undercovers
STUI photo(s) are required where indicated by STUI camera icon
*Refer to TSB 22-FL-005H when defueling the hydrogen tanks
End of
procedure
**Refer to shop manual to perform leak check and repair leaks
Nexo (FE) > 2019 > 113KW > Hydrogen Storage System > Repair
Procedures> Hydrogen Gas Leak Test > For Hydrogen Storage System
(HSS)
TSB #: 22-01-080H
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SUBJECT:
HMU UPDATE & PRESSURE RELIEF VALVE (PRV) REPLACEMENT (SERVICE CAMPAIGN T9A)
NOTICE
•
Check vehicle for outstanding campaigns requiring defueling and perform all repairs
NOTICE
•
•
•
•
•
•
•
•
Verify the vehicle is affected by checking the HMU control unit ROM ID version and
referencing the ROM ID Information Table before updating the control unit software.
!
CAUTION
Run the fuel cell a sufficient amount of time to ensure that the 12-volt auxiliary battery is
sufficiently charged for the update. Turn off the vehicle after 12-volt auxiliary battery is
charged.
Ensure the 12-volt battery will not become discharged during the update by turning off all lights
and accessories, heater/air conditioner, fan, audio, heated seats, rear defroster, etc.
Do not leave the headlight switch in auto mode.
Before performing the update, set the POWER button to the ON position. To set the POWER
button to the ON position, press the button two times without pressing the brake pedal.
Do not start the fuel cell.
Do not turn OFF the POWER button during the update.
Do not disconnect any cables connected to the vehicle or GDS-M during the update
NOTICE
•
•
Confirm your GDS-M has the most recent software version. If not, connect the GDS-M
Mobile to an Internet port, open the GDS-M home page and select “Internet Update.” Refer
to www.hyundaitechinfo.com if necessary.
If you encounter GDS-M related problems, call the GIT Helpline at 888-437-0308.
NOTICE
•
When the vehicle auxiliary 12-volt battery has low voltage, the GDS-M will trigger a Low
Battery Voltage Warning. If this Warning occurs, then perform A or B as follows.
A. Connect the battery to a fully charged battery jump pack or GR8 charger using “Power Supply
Mode” to continue the software update.
B. Select “BACK” to exit the SW update. Then, start the fuel cell and let it run with until the
auxiliary 12-volt battery is sufficiently charged. Return to the software update after charging
the battery to prevent ECM damage.
TSB #: 22-01-080H
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HMU UPDATE & PRESSURE RELIEF VALVE (PRV) REPLACEMENT (SERVICE CAMPAIGN T9A)
SERVICE PROCEDURE: HMU Update
Connect the VCI-II into the vehicle’s driver side
instrument panel OBD-II port and verify the
device is operational.
Do not set up the trigger module.
NOTICE
•
•
GDS-M control unit upgrading operates with wireless communication ad Wi-Fi direct.
It is possible to perform the update via USB cable between the tablet PC and VCI-II.
Ensure the tablet battery has reasonable charge before starting the update.
NOTICE
•
•
You must initially perform GDS-M HMU Update in Auto Mode.
If the ECM Update starts but then fails in Auto Mode, perform the update in Manual
Mode to recover.
A. Automatic GDS-M Update Procedure
1. Enter the vehicle’s information and on the next screen select ECU Upgrade.
2. Select Auto Mode and then select System, HMU.
3. Read information and select ID check.
4. GDS-M will read the current vehicle ROM ID and check for the newest update event.
5. Select the upgrade event.
"816.FE REGULATOR COMPLEMENTARY LOGIC (HMU SOFTWARE)"
6. If the low battery warning message appears,
then select the BACK arrow
and run the
fuel cell to ensure the battery is adequately
charged for the update.
7. Update (1/2) will begin and progress will be displayed on the bar graph.
8. Update (2/2) will begin and progress will be displayed on the bar graph.
9. After update (2/2) is complete, turn off the ignition for 10 seconds.
10. Turn the ignition to the ON position and press OK to continue according to information displayed
on the screen. Do not start the fuel cell. Do not put into READY mode.
11. Select OK on the final screen and the update is complete.
TSB #: 22-01-080H
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HMU UPDATE & PRESSURE RELIEF VALVE (PRV) REPLACEMENT (SERVICE CAMPAIGN T9A)
12. Check for any DTCs created by the update and clear the codes.
13. Start the fuel cell (READY Mode) to confirm if the vehicle is operating properly.
NOTICE
•
•
Only perform the manual update if the automatic update fails.
If automatic update fails, turn the ignition off for about 10 seconds. Place it back into the
ON position to reset the control unit before performing the manual update
B. Manual GDS-M Update Procedure
1. Within the upgrade screen, select Manual Mode, then select upgrade event.
2. Select the control unit part number with reference to the ROM ID Information Table as listed
below in this TSB. Then select Upgrade.
816.FE REGULATOR COMPLEMENTARY LOGIC (HMU SOFTWARE)"
3. Enter the password from the password table located at the below in this TSB and press OK.
4. If the low battery warning message appears,
then select the BACK arrow
and run the
fuel cell to ensure the battery is adequately
charged for the update.
5. Update (1/2) will begin and progress will be displayed on the bar graph.
6. Update (2/2) will begin and progress will be displayed on the bar graph.
7. After update (2/2) is complete, turn off the ignition for 10 seconds.
8. Turn the ignition to the ON position and press OK to continue according to information displayed
on the screen. Do not start the fuel cell. Do not put into READY mode.
9. Select OK on the final screen and the update is complete.
10. Check for any DTCs created by the update and clear the codes.
11. Put the vehicle into READY mode to confirm the vehicle is operating properly.
TSB #: 22-01-080H
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HMU UPDATE & PRESSURE RELIEF VALVE (PRV) REPLACEMENT (SERVICE CAMPAIGN T9A)
SUBJECT:
ROM ID Reference Table
DEL
HMU P/No.
35908-M5000
FE
ROM ID
OLD
NEW
3700R
3500R
3600R
3700R
3910R
4030R
Manual Mode Password Information Tables:
EVENT #
MENU
PASSWORD
816
FE HMU 35908-M5000
0304
TSB #: 22-01-080H
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SUBJECT:
HMU UPDATE & PRESSURE RELIEF VALVE (PRV) REPLACEMENT (SERVICE CAMPAIGN T9A)
SERVICE PROCEDURE: Depleting Residual Fuel Supply Pressure & Defueling
1.
Place the vehicle in READY mode using the
START / STOP push button. Photograph the fuel
gauge level and a paper showing the last 6 digits
of the VIN or RO #, and the date of defueling.
Similar to the photo to the right.
STUI
Using STUI, photograph the fuel gauge.
Include in the photos a piece of paper
containing the last 6 digits of the VIN or
the RO #, and the date of the defueling.
Ensure the photo is in focus and captures
the fuel gauge display, odometer, and
note. Upload the photo to STUI.
2.
Connect the GDS-M, select the HMU, and then
confirm the storage tank pressure.
3.
If storage tank pressure is less than or equal to
1,100 PSI, then deplete residual fuel supply
pressure by referring to TSB 22-FL-005H—
VENTING NEXO FUEL CELL ELECTRIC
VEHICLES or the latest version.
4.
If storage tank pressure is greater than 1,100
PSI, then defuel storage tanks to less than 1,100
PSI and deplete residual fuel supply pressure by
referring to TSB 22-FL-005H—VENTING NEXO
FUEL CELL ELECTRIC VEHICLES or the latest
version.
TSB #: 22-01-080H
Icon illuminates when the
vehicle is in READY mode.
Page 9 of 18
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HMU UPDATE & PRESSURE RELIEF VALVE (PRV) REPLACEMENT (SERVICE CAMPAIGN T9A)
12 volt and High Voltage Circuit Disconnection
1.
In the rear cargo area, remove the floorboard and
cargo tray to access the 12 volt battery connector
and high voltage battery Safety Plug.
TSB #: 22-01-080H
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2.
3.
HMU UPDATE & PRESSURE RELIEF VALVE (PRV) REPLACEMENT (SERVICE CAMPAIGN T9A)
Disconnect the 12 volt battery negative (-)
connector.
!
WARNING
•
Electrocution hazard - Refer to the shop manual - Battery Control System
> High Voltage Battery Handling Guide and follow the High Voltage Shutoff Procedure.
•
Before performing the service procedure, ensure proper Personal
Protection Equipment (PPE) is worn to prevent injury. Verify PPE is not
expired and in proper working condition.
Remove the metal shield to access the High
Voltage Safety Plug.
TSB #: 22-01-080H
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HMU UPDATE & PRESSURE RELIEF VALVE (PRV) REPLACEMENT (SERVICE CAMPAIGN T9A)
4.
Follow A-D below to remove the orange high
voltage safety plug.
Store the removed safety plug in a secure location
outside and away from the vehicle.
5.
Wait 5+ minutes to allow the high voltage system
capacitor to discharge.
TSB #: 22-01-080H
Safety Plug Removal
Page 12 of 18
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6.
HMU UPDATE & PRESSURE RELIEF VALVE (PRV) REPLACEMENT (SERVICE CAMPAIGN T9A)
Open the hood. Remove the junction box trim and
cover.
High voltage junction box cover: Assembly bolt
torque 7.2~8.7lb-ft
(1.0 ~ 1.2 kgf.m, 9.8 ~ 11.8 N.m)
Junction Box Trim
HVJB Cover
7.
Using a Digital Volt Ohm Meter (DVOM), measure
the voltage across the inverter positive and
negative bus bar terminals to inspect for capacitor
discharge. If the measured voltage is below 30
volts, the High Voltage Circuit is properly shut
down.
!
•
DANGER
Electrocution hazard - The High
Voltage Junction Box (HVJB) may be
electrically energized up to 450 volts.
TSB #: 22-01-080H
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Page 13 of 18
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HMU UPDATE & PRESSURE RELIEF VALVE (PRV) REPLACEMENT (SERVICE CAMPAIGN T9A)
SUBJECT:
8.
Close the manual valves on all 3 hydrogen tanks.
Using a 6mm Allen wrench turn the manual valve
clockwise until it stops.
Exceeding closing torque specification, may
damage the manual valve.
Closing Torque:
3.6 ~ 7.2 lb-ft (4.9 ~ 9.8 Nm)
NOTICE
•
9.
Some components of the manual valve
may be damaged if over-torqued.
Remove the pressure relief valve (PRV) (A) using
a 24mm socket & ratchet. Turn the PRV
counterclockwise to remove. Use a 32mm wrench
to hold the Regulator while removing the PRV.
A
NOTICE
•
Be careful not to damage the fuel
supply tube and regulator mounting
bracket.
TSB #: 22-01-080H
Page 14 of 18
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10.
HMU UPDATE & PRESSURE RELIEF VALVE (PRV) REPLACEMENT (SERVICE CAMPAIGN T9A)
Remove the PRV sealant using a razor blade.
NOTICE
•
•
Ensure work area cleanliness to prevent
foreign substances from entering the
PRV openings to prevent clogging the
PRV.
Do not use an air gun to remove foreign
substances.
AFTER
CLEANING
BEFORE
CLEANING
11.
Install the new PRV (B) turning it clockwise.
Tightening Torque:
54.2 ~65.8 lb-ft (73.5~89.2 Nm)
B
i Information
•
Keep the PRV vertical during
installation so that internal components
will not fall out of the PRV.
TSB #: 22-01-080H
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12.
HMU UPDATE & PRESSURE RELIEF VALVE (PRV) REPLACEMENT (SERVICE CAMPAIGN T9A)
Before applying sealant in the next step, take a
photograph of the newly installed PRV and a paper
showing the last six digits of the VIN or RO #, and
the date of installation. Similar to the photo to the
right.
STUI
Using STUI, photograph the newly
installed PRV. Include in the photo a
piece of paper containing the last 6
digits of the VIN or the RO #, the date of
the installation. Ensure the PRV, and
note are captured and in focus. Upload
the photo to STUI.
13.
Apply the sealant (C) between the PRV and the
body of the high-pressure regulator.
NOTICE
•
Use gas detector or Snoop liquid leak
detector to test if there is any gas
leakage.
•
Do not apply Snoop liquid on the part
where the sealant is applied.
•
If there is any leakage on the part where
the sealant is applied, the sealant may
inflate.
•
Apply the sealant by using the nozzle
included in the box.
•
TSB #: 22-01-080H
Page 16 of 18
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14.
HMU UPDATE & PRESSURE RELIEF VALVE (PRV) REPLACEMENT (SERVICE CAMPAIGN T9A)
Open the manual valves on all 3 hydrogen tanks.
Using a 6mm Allen wrench turn the manual valve
counter-clockwise until it stops then rotate manual
valve one half turn clockwise.
Exceeding opening torque specification, may
damage the manual valve.
Opening Torque:
3.6 ~ 7.2 lb-ft (4.9 ~ 9.8 Nm)
NOTICE
•
Some components of the manual valve
may be damaged if over-torqued.
15.
Reconnect 12-volt and high-voltage batteries. Refer to page 10.
16.
With the vehicle in ready mode, perform a leak check of lines, fittings and components removed
and/or replaced, using a Hydrogen leak detector.
Refer to the shop manual:
Nexo (FE) > 2019-2022 > 113KW > Hydrogen Storage System > Repair Procedures>
Hydrogen Gas Leak Test > For Hydrogen Storage System (HSS)
If no leak is found, then proceed to the next step. Do not reinstall the under covers until final leak
check is performed.
If a leak is found. Refer to TSB 22-FL-005H—VENTING NEXO FUEL CELL ELECTRIC VEHICLES
to perfom “Preparation for Replacement of Hydrogen Components” and “Depleting Residual Fuel
Supply Pressure”. Repair the leak(s), then perform this step again until no leak is found.
17.
Refuel hydrogen storage tanks to full at a local hydrogen station.
Refer to the station websites below to confirm station availability before driving or towing vehicle to
the station:
• https://cafcp.org/stationmap
• https://h2-ca.com/
TSB #: 22-01-080H
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18.
HMU UPDATE & PRESSURE RELIEF VALVE (PRV) REPLACEMENT (SERVICE CAMPAIGN T9A)
After refueling the vehicle, use the Push Button
Start Stop (PBSS) switch and place the vehicle
systems into the READY mode. Photograph the
fuel level gauge and a paper showing the last six
digits of the VIN or RO #, and the date of refueling.
Similar to the photo to the right.
STUI
Using STUI, photograph the fuel gauge.
Include in the photo a piece of paper
containing the last 6 digits of the VIN or
the RO #, the date of the refueling.
Ensure the fuel gauge display,
odometer, and note are captured and in
focus. Upload the photo to STUI.
19.
After the Hydrogen tanks have been refueled. Put the vehicle on a lift and place the vehicle into
READY mode using the PBSS. Perform a leak check of hydrogen fuel components that were
replaced, using a Hydrogen leak detector.
Refer to the shop manual:
Nexo (FE) > 2019-2022 > 113KW > Hydrogen Storage System > Repair Procedures>
Hydrogen Gas Leak Test > For Hydrogen Storage System (HSS)
20.
If a leak is found. defuel tanks to 1,100 PSI or less and Refer to TSB 22-FL-005H—VENTING
NEXO FUEL CELL ELECTRIC VEHICLES “Preparation for Replacement of Hydrogen
Components” and “Depleting Residual Fuel Supply Pressure”. Repair the leak(s), then perform
steps 15 - 19 on pages 17 and 18 again until no leak is found.
21.
If no leak is found, then replace the undercovers.
22.
The procedure is complete.
TSB #: 22-01-080H
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