Hyundai Sonata Plug-in Hybrid Emergency Response Manual
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Hyundai Sonata Plug-in Hybrid Emergency Response Manual

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Plug-in
Emergency Response Guide
NEW THINKING.
NEW POSSIBILITIES.

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Summary of Contents for Hyundai Sonata Plug-in Hybrid

  • Page 1 Plug-in Emergency Response Guide NEW THINKING. NEW POSSIBILITIES.

  • Page 2: Table Of Contents

    Contents Introduction Sonata Plug-in Hybrid Identification - General Vehicle Description - Identifying a Hyundai Plug-in Hybrid Sonata Plug-in Hybrid main systems - Key Specifications - Vehicle Components Location - Vehicle Components - Plug-in Hybrid System Operation - Airbag system (SRS : Supplemental Restraint System)

  • Page 3: Introduction

    The purpose of this document is to familiarize emergency responders and the towing/roadside assistance industry with the proper methods to handle the Hyundai Sonata Plug-in 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.

  • Page 4: Sonata Plug-In Hybrid Identification

    Sonata Plug-in Hybrid Identification General Vehicle Description The Hyundai Sonata Plug-in Hybrid is built on a conventional Sonata chassis and therefore the four door sedan looks very similar to its conventional counterpart with a few notable exceptions. The safest method is to assume that any Sonata you respond to is a Hybrid vehicle until proven otherwise.
  • Page 5 Sonata Plug-in Hybrid Identification VIN number The Vehicle Identification Number (VIN) identifies the Plug-in Hybrid Vehicle with a “2” displayed in the 6th position, as shown in the below drawing. The VIN is punched on the floor under the passenger seat. The number 2 in the 6th character of the VIN indicates that it is a Plug-in Hybrid with 2.0 gasoline engine.
  • Page 6 Sonata Plug-in Hybrid Identification Engine Compartment Unlike the conventionally powered Sonata, the Hybrid version has a plastic engine cover with “hybrid” clearly shown on it. Additionally, there are orange colored high- voltage electrical cables in the engine compartment. Vehicle Underside...
  • Page 7 Sonata Plug-in Hybrid Identification Charging Port The Charging Port is located on the front fender covered by the charging port cap and it has one port for AC normal charging. How to open the charging port 1. Depress the brake pedal and apply the parking brake.
  • Page 8 Sonata Plug-in Hybrid Identification Plug-in Hybrid Vehicle Cluster Instrument Panel The Plug-in Hybrid Vehicle Instrument Cluster Panel displays the Plug-in Hybrid vehicle specific features that identify the Sonata as a plug-in hybrid vehicle. Also “plug-in hybrid” symbol is located at the upper of the left side of the Instrument Cluster Penal.

  • Page 9: Sonata Plug-In Hybrid Main Systems

    Sonata Plug-in Hybrid main systems Key Specifications Item Plug-in Hybrid Engine Displacement 2.0L GDI Hybrid Engine Transmission Type 6speed Automatic Transmission Capacity Fuel Tank 14.5 / 55 (U.S.gal / ℓ ) Type Permanent Magnet Synchronous Motor Motor Max. Output (kW)

  • Page 10: Vehicle Components Location

    Sonata Plug-in Hybrid main systems Vehicle Components Location Electric Drive Motor High-Voltage Cable 12V Auxiliary Battery Hybrid Starter Generator (HSG) High-Voltage Battery Assembly Electric AC Compressor On Board Charger HPCU (OBC) On-Board Charger : Battery charging equipment (AC → DC)

  • Page 11: Vehicle Components

    Sonata Plug-in Hybrid main systems Vehicle Components 12V Auxiliary Battery The 12V Auxiliary Battery is located in the trunk on the passenger side of the vehicle and is accessed by removing a small cover. This battery powers all of the standard electronics like radio, air conditioner, etc.
  • Page 12 Sonata Plug-in Hybrid main systems Hybrid Power Control Unit The Hybrid Power Control Unit (HPCU) assembly consists of three components: a Hybrid Control Unit (HCU), an Inverter (Motor Control Unit (MCU)) as well as a Low-voltage DC-DC Converter (LDC). The HPCU assembly...
  • Page 13 Sonata Plug-in Hybrid main systems Air Conditioning Compressor The Air Conditioning Compressor is mounted to the engine directly below the HSG. It is also powered by the high-voltage system, so its electrical connection via an orange HV cable is easily noticeable as well.

  • Page 14: Plug-In Hybrid System Operation

    Sonata Plug-in Hybrid main systems Plug-in Hybrid System Operation Operating Parameters The Plug-in Hybrid Sonata has two modes of using charged electricity. One is Charge Depleting (CD) mode where the vehicle is propelled by the electric motor only until it depletes to the predefined level of high-voltage battery.
  • Page 15 High-Voltage Battery and the Hybrid Power Control Unit. High-Voltage Safety System There are multiple safety systems incorporated into the Sonata Plug-in Hybrid. The system that protects the High-Voltage Electrical System is called the Battery Management System (BMS). The BMS is...

  • Page 16: Airbag System (Srs : Supplemental Restraint System)

    Airbag system (SRS : Supplemental Restraint System) Airbag Seven airbags are installed in the Sonata Plug-in Hybrid as shown below. Before starting any emergency procedure, make sure the vehicle ignition is turned off, disconnect the negative cable from the 12V auxiliary battery to prevent accidental deployment of airbags.
  • Page 17 Sonata Plug-in Hybrid main systems Seat Belt Pretensioners The Sonata Plug-in Hybrid is equipped with driver’s and front passenger’s seat belts with pretensioners. When the seat belt pretensioners are activated in a collision, a loud noise may be heard and fine dust, which may appear to be smoke, may be visible in the passenger compartment.

  • Page 18: Emergency Procedures

    Emergency procedures Initial Response: The following procedures should be used whenever you are dealing with a Sonata Plug-in Hybrid at an emergency scene. All other operations should be consistent with your department’s standard operating procedures or guides. Identify When dealing with a Sonata 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.
  • Page 19 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 Sonata Plug-in 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.
  • Page 20 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.
  • Page 21 Emergency procedures 2. If necessary, lower the windows, unlock the doors and open the trunk as required, before disconnecting the 12V battery. Once the 12V battery is disconnected, power controls will not operate. Smart Key 3. Before disconnecting the 12V battery, move the smart key at least 2 meters away from the vehicle to prevent accidental restart.
  • Page 22 Emergency procedures Ⅱ. Disabling the system – IG Relay Removal (Alternate Method) 1. Open the hood. 2. Remove the engine compartment fuse box cover. 3. If necessary, lower the windows, unlock the doors and open the trunk as required, before disconnecting the 12V battery.
  • Page 23 Emergency procedures 5. Use the following procedure to remove the safety plug and disable the high voltage battery: a) Remove the installation bolts (A), and a) Remove the safety plug (C) using the then remove the safety plug cover(B). following procedure : A: Unlock →...

  • Page 24: Extraction Operations

    Extrication tools and procedure When responding to an incident involving a Sonata Plug-in Hybrid, we recommend that the first responders follow their organization’s standard operating procedures for assessing and dealing with vehicle emergencies.

  • Page 25: Vehicle Fire

    After Initial Emergency Response Procedures have been applied, Firefighting Procedures may begin. Hyundai recommends that each response team follow their own department’s standard operating procedures for fighting vehicle fires in combination with the Sonata Plug-in Hybrid specific details that are covered in this section.

  • Page 26: High-Voltage Battery Damage And Fluid Leaks

    Emergency procedures High-Voltage Battery Damage and Fluid Leaks The HV Battery assembly is enclosed in a sturdy metal case that is rigidly mounted to structural components of the vehicle. This construction helps prevent damage to the HV Battery assembly even in severe crashes. This section provides emergency responders with information regarding how to mitigate the severity of a damaged HV Battery assembly or gel electrolyte spill, however unlikely that might be.

  • Page 27: Roadside Assistance

    17 to 21. When towing Sonata Plug-in Hybrid vehicle, all wheels should be off the ground and not in contact with the road.

  • Page 28: To Jump Start The Car

    7. Remove the negative terminal cable first, and then remove the positive terminal cable. If the cause of your battery discharging is not apparent, we recommend that the system be checked by an authorized HYUNDAI dealer or Hyundai Motor America.
  • Page 29 Ⓒ2015 Hyundai Motor Company All rights reserved. This document may not be altered without the written permission of Hyundai Motor Company.

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