Nuvera® Fuel Cell System C95A-33 Service Manual - PDF DOWNLOAD

Service Manual Fuel Cell System C95A-33

31002993 | 04/2020

NOTICE OF PROPRIETARY PROPERTY This document and the information contained in it are the proprietary property of Nuvera Fuel Cells LLC. This document is intended solely for the internal use of the recipient and may not be used outside the recipient's organization nor distributed to third parties without the express prior written consent of Nuvera Fuel Cells LLC.

© Nuvera Fuel Cells, LLC. 2020 All rights reserved.

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Nuvera® Fuel Cell System C95A-33 Service Manual

Contents

Table of Contents General Information Safety information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 Personal Protective Equipment (PPE). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 General hazards, warnings, and cautionary statements. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Hydrogen-specific concerns. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Swagelok® fitting procedures Swagelok® procedures. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Scope. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Safety and warnings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Tools required. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Initial seating. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Disassembly and reseating. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6 Preparing for service and maintenance Components of the Nuvera® fuel cell system. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Warning labels. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Required procedures prior to service. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Scope. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Preparing the truck and removing the fuel cell. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Scope. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Safety and warnings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Tools required. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Secure the truck. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10 Prepare the truck. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10 Remove the Fuel Cell System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Preparing the Nuvera fuel cell system for service. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 Scope. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 Safety and warnings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 Tools required. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 Remove the air filter access panel. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 Install the air filter access panel. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 Discharging and recharging the ultracapacitors. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 Scope. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 Safety and warnings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 Tools required. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 I

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Nuvera® Fuel Cell System C95A-33 Service Manual

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Preparing for service and maintenance Discharge the ultracapacitors. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 Recharge the ultracapacitors. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 Removing and installing the main cover. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 Scope. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 Safety and warnings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 Tools required. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 Discharge ultracapacitors. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 Remove main cover. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 Install main cover. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 Remove and replace lifting eye plate. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 Working with charged ultracapacitors with cover removed. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 Scope. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 Safety and warnings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 Tools required. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 Procedure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 Personal Protective Equipment (PPE). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 Remove main cover. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 Working with charged ultracapacitors. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 Start into off mode. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 Safety and warnings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 Tools required. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 Start into off mode. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 Leak check coolant loop. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 Safety and warnings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 Tools required. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 Leak check coolant loop. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 Leak check anode loop. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 Safety and warnings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 Tools required. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 Leak check anode loop. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 Leak check H2 plumbing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28 Safety and warnings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28 Tools required. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28 Pressurize H2 Plumbing via Nuvera® Fuel Cell System Service Tool. . . . . . . . . . . . . . . . . . . . . . . . . 28 Vent hydrogen from engine plumbing lines. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 Safety and warnings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 Tools required. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 Set up for external supply of nominal bus voltage. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32 II

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Nuvera® Fuel Cell System C95A-33 Service Manual

Contents

Preparing for service and maintenance Safety and warnings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32 Tools required. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32 Revert to normal ultracaps connection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34 Safety and warnings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34 Installing Vector VN1610 drivers. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .35 Safety and warnings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35 Parts and materials required. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .35 Install. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35 Retrieving data from vector data-logger. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37 Safety and warnings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37 Parts and materials required. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .37 Load the software. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37 Procedure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38 Descriptions of adopted conversion profiles. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40 General Settings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40 Advanced Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40 Splitting Options. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41 Programming the VSM (Vehicle System Manager). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42 Safety and warnings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42 Parts and materials required. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .42 Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .42 Install. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42 Program. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .43 Set up flags for VSM software 3.0.0. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46 Safety and warnings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46 Tools required. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46 Procedure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46 Removing and installing the engine sled. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49 Scope. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49 Safety and warnings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49 Tools required. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49 Parts and materials required. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .49 Remove. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49 Install. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53 PowerEdge Replacement Stack Commissioning and Dormant BBR Startup Procedure (Class I and II).

53 Scope. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53 Safety and warnings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53 III

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Nuvera® Fuel Cell System C95A-33 Service Manual

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Preparing for service and maintenance Tools required. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54 Parts and materials required. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .54 Replacing or restarting a stack. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54 Service procedures Opening and closing storage tank valves. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .57 Scope. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57 Safety and warnings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57 Tools required. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57 Open and close storage tank solenoid valves. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57 Draining and filling coolant. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59 Scope. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59 Safety and warnings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59 Tools required. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59 Drain coolant. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59 Refill coolant. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .60 Draining and filling coolant (systems with vented stack). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62 Scope. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62 Safety and warnings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62 Tools required. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62 Tools required. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63 Procedure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63 Cleaning. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .69 Replacing the air filter. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70 Scope. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70 Safety and warnings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70 Parts and materials required. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .70 Remove. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70 Install. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71 Replacing the coolant filter (fuel cell systems up to and including S/N A2D1S01500R). . . . . . . . . . . . 72 Scope. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72 Safety and warnings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72 Tools required. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72 Parts and materials required. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .72 Remove. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72 Install. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73 Replacing the coolant filter (fuel cell systems S/N A2D1S01501R and after). . . . . . . . . . . . . . . . . . . . . 74 IV

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Service procedures Scope. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74 Safety and warnings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74 Tools required. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74 Parts and materials required. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .74 Remove. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74 Install. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75 Replacing the wicking filter. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76 Scope. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76 Safety and warnings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76 Parts and materials required. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .76 Remove. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76 Install. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77 Removing and installing the radiator. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78 Scope. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78 Safety and warnings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78 Tools required. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78 Remove. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78 Clean. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80 Install. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80 Replacing the DPS (fuel cell systems up to and including S/N A2D1S01500R). . . . . . . . . . . . . . . . . . . . 81 Scope. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81 Safety and warnings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81 Parts and materials required. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .81 Remove. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81 Install. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82 Replacing the DPS (fuel cell systems S/N A2D1S01501R and after). . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82 Scope. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82 Safety and warnings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82 Parts and materials required. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .82 Remove. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83 Adjust the DPS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83 Install. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83 Replacing the air compressor (fuel cell systems up to and including S/NA2D1S01500R). . . . . . . . . . 84 Scope. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84 Safety and warnings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84 Tools required. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84 Prepare. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84 Remove. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84 V

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Service procedures Install. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89 Replacing the air compressor (fuel cell systems S/N A2D1S01501R and after). . . . . . . . . . . . . . . . . . . 90 Scope. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90 Safety and warnings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90 Tools required. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91 Prepare. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91 Remove. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91 Install. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94 Replacing the main fan relay. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95 Scope. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95 Safety and warnings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95 Tools required. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95 Prepare. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95 Remove. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96 Install. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97 Replacing the humidifier bypass valve. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99 Scope. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99 Safety and warnings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99 Tools required. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99 Prepare. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99 Remove. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99 Install. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101 Replacing the trican sensor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102 Scope. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102 Safety and warnings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102 Tools required. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102 Prepare. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102 Remove. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102 Install. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103 Replacing the three-way valve (fuel cell systems up to and including S/N A2D1S01500R). . . . . . . . 104 Scope. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104 Tools required. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104 Parts/Materials required. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104 Prepare. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104 Remove. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104 Install. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105 Replacing the three-way valve (fuel cell systems S/N A2D1S01501R and after). . . . . . . . . . . . . . . . . 106 Scope. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106 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Nuvera® Fuel Cell System C95A-33 Service Manual

Contents

Service procedures Tools required. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106 Parts/Materials required. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106 Prepare. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106 Remove. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106 Install. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107 Replacing the water level sensor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109 Scope. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109 Safety and warnings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109 Tools required. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109 Prepare. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109 Remove. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109 Install. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110 Replacing the fuel cell stack. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .111 Scope. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111 Safety and warnings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111 Tools required. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111 Parts and materials required. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .111 Prepare . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .111 Remove. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111 Install. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115 Replacing the humidifier. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116 Scope. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116 Safety and warnings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116 Tools required. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116 Prepare. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117 Remove. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117 Install. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119 Replacing thermocouples (TT304 and TT351). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120 Scope. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120 Safety and warnings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120 Parts and materials required. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .120 Remove. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120 Install. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121 Replacing pressure switch (PS104) or pressure transducer (PT157). . . . . . . . . . . . . . . . . . . . . . . . . . . 121 Scope. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121 Safety and warnings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122 Parts and materials required. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .122 Remove. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122 VII

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Nuvera® Fuel Cell System C95A-33 Service Manual

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Service procedures Install. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123 Replacing fuses (F02, F05, F06). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124 Scope. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124 Safety and warnings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124 Tools required. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124 Remove fuses from the fuse box. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124 Install fuses into the fuse box. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125 Replacing relays (K06 and K14). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126 Scope. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126 Safety and warnings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126 Tools required. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126 Remove relays. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126 Install relays. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127 Replacing and recharging the 24 Volt battery system. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128 Scope. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128 Safety and warnings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128 Tools required. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128 Parts and materials required. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .128 Recharge. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128 Remove. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129 Install. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129 Storing the Lithium-ion batteries. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130 Replacing drain valve (XV154) and purge valve (XV155). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 132 Scope. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 132 Safety and warnings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 132 Tools required. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 132 Remove. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 132 Install. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133 Replacing the ejector (PCE103). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134 Scope. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134 Safety and warnings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134 Tools required. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134 Parts and materials required. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .134 Prepare. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134 Remove. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134 Install. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 137 Replacing the ultracapacitor module. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 140 Scope. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 140 VIII

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Nuvera® Fuel Cell System C95A-33 Service Manual

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Service procedures Safety and warnings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 140 Tools required. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 140 Parts and material required. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 140 Prepare. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 140 Remove. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 141 Install. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 144 Replacing the DC/DC unit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 145 Scope. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 145 Safety and warnings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 145 Tools required. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 145 Remove. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 145 Install. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 148 Replacing the motor controller. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 149 Scope. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 149 Safety and warnings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 149 Tools required. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 149 Parts and materials required. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .149 Prepare. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 149 Remove. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 149 Install. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 150 Replacing the CVM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 152 Scope. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 152 Safety and warnings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 152 Tools required. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 152 Prepare. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 152 Remove. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 152 Install. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 154 Replacing the VSM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .155 Scope. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 155 Safety and warnings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 155 Tools required. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 155 Prepare. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 155 Remove. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 155 Install. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 156 Replacing the heater relay. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 157 Scope. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 157 Safety and warnings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 157 Tools required. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 157 IX

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Service procedures Remove. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 157 Install. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 158 Replacing solenoid valve (XV101). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 159 Scope. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 159 Safety and warnings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 159 Tools required. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 159 Remove. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 159 Install. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 161 Replacing FL190, PCV192 and PCV193. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .162 Scope. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 162 Safety and warnings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 162 Tools required. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 162 Remove. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 162 Install. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 164 Replacing FV194 and OR198. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 165 Scope. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 165 Safety and warnings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 165 Tools required. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 165 Remove. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 165 Install. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 167 Replacing the vent OK or watchdog timer (fuel cell systems up to and including S/N A2D1S01500R).

167 Scope. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 167 Safety and warnings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 167 Tools required. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 167 Prepare. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 167 Remove. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 168 Install. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 168 Replacing the vent OK or watchdog timer (fuel cell systems S/N A2D1S01501R and after). . . . . . . 169 Scope. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 169 Safety and warnings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 169 Tools required. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 169 Prepare. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 169 Remove. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 169 Install. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 170 Periodic maintenance procedures. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 172

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Special Tools Special tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 173

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List of Figures Figure 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36

Title

Page

Insert tube into fitting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4 6 o'clock position. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 9 o'clock position. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Marking line. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Gap inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Marking line. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Internal fuel cell components. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 These warning labels will be found on the Nuvera® Fuel Cell System. . . . . . . . . . . . . . . . . . . . . . . . .8 Measure connector with multimeter. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Air filter access panel. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 Connect fuel cell to external load bank. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13 Charge Ultracaps. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 Discharge Ultracaps. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 Lifting eyes: Low pressure compartment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 Attach lifting chain to main cover. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 Remove/Install main cover. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 Lifting eyes: Low pressure compartment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 Start system into Off mode. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 System is in 'off' mode. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 Coolant Loop Leak Check. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 Anode Loop Leak Check. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 Pressurize H2 plumbing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28 Pressurize H2 prompt. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29 Vent Hydrogen from Plumbing Lines. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31 13 mm wrench. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32 Tape buss bar. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33 Power supply. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33 Connect power supply leads. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33 Download software. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .35 Select Driver/Firmware. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35 Setup. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36 Install. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36 Select software. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37 Download software. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .38 Logger Device. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38 Set up logger. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38 XII

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List of Figures Figure 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70 71 72

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Page

Insert Macro. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38 Hexadecimal notation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .39 Splitting Options tab. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39 Select ellipsis button. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39 Convert logged data. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39 Delete data from SD card. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .40 General Settings of conversion profile. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40 Advanced Settings of conversion profile. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .40 Splitting Options of conversion profiles. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41 Select micro controller. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43 iFak driver. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43 Configure Vector CanCard Driver. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44 Configure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .44 Ellipses button. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44 Progress bar. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45 Start system into Off mode. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46 Select VSM Flags. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47 Set flags. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47 VSM Flags Table. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47 VSM Flags Table_2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48 Stop system. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48 High pressure compartment top access panel. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .50 Disconnect/Connect fuel line. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50 Disconnect/Connect dewatering line. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50 Disconnect/Connect high pressure harness bulkhead connector. . . . . . . . . . . . . . . . . . . . . . . . . . . 50 Lifting eyes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51 Feeding tow strap through lifting eyes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51 D-clamp with tow strap. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51 Attach tow straps to lifting chain. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51 Remove/Install sled from fuel cell. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52 Service tool GUI. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54 High pressure compartment access panel. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57 Storage tank shutoff valve. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58 Heater (HTR303), fuel cell systems up to and including S/N A2D1S01500R. . . . . . . . . . . . . . . . . . .60 Heater (HTR303), fuel cell systems S/N A2D1S01501R and after. . . . . . . . . . . . . . . . . . . . . . . . . . . .60 Coolant Fill . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61 XIII

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List of Figures Figure 73 74 75 76 77 78 79 80 81 82 83 84 85 86 87 88 89 90 91 92 93 94 95 96 97 98 99 100 101 102 103 104 105 106 107 108

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Coolant recovery tank. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63 Drain coolant. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63 Plug the hose. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64 Heater (HTR303), fuel cell systems up to and including S/N A2D1S01500R. . . . . . . . . . . . . . . . . . .64 Heater (HTR303), fuel cell systems S/N A2D1S01501R and after. . . . . . . . . . . . . . . . . . . . . . . . . . . .64 Radiator cap. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65 Funnel adapter. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .65 Medium radiator cap. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65 Funnel extension. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66 Funnel. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66 Bleed port plug. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .66 Coolant suction tube. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .66 coolant suction and discharge tubes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67 Coolant fill. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .67 Coolant pump. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .68 Coolant fill neck. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69 Air inlet assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70 Air filter. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71 Air filter O-ring. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71 Coolant filter hardware. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72 Remove coolant filter. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73 Coolant filter hardware. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74 Remove coolant filter. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75 Radiator cover. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76 Wicking filter. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76 Radiator with wicking filter removed. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77 Install new wicking filter. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77 Fan connectors. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .78 Radiator mounting, fuel cell systems up to and including S/N A2D1S01500R. . . . . . . . . . . . . . . . .79 Radiator mounting, fuel cell systems S/N A2D1S01501R and after. . . . . . . . . . . . . . . . . . . . . . . . . . 79 Bottom radiator mounting bracket. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80 Remove radiator. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80 Check radiator fan clearance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .81 DPS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82 DPS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83 Cable guard. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .85 XIV

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List of Figures Figure 109 110 111 112 113 114 115 116 117 118 119 120 121 122 123 124 125 126 127 128 129 130 131 132 133 134 135 136 137 138 139 140 141 142 143 144

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Coolant filter and fuse box. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85 Vent OK timer bolt. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86 Compressor to air cooler hose. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86 Disconnect batteries. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86 Relays. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .87 Mounting bolts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .87 Coolant pump intake hose. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .88 Compressor frame bolts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .88 Compressor mounting bolts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89 Compressor motor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89 Cable guard. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .91 Coolant filter and bracket. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92 Fuse box bracket. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92 Compressor to air cooler hose. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92 Compressor mounting clamp. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92 Upper frame bolts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93 Lower frame bolts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93 Service panel. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93 Compressor connectors. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93 Compressor mounting bolts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94 Main fan relay location, fuel cell systems up to and including . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96 Main fan relay. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96 Remove electrical panel, fuel cell systems and after. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97 Main fan relay. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97 Humidifier valve hose, fuel cell systems up to and including S/N A2D1S01500R. . . . . . . . . . . . . 100 Humidifier valve hose, fuel cell systems S/N A2D1S01501R and after. . . . . . . . . . . . . . . . . . . . . . 100 Humidifier valve. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100 Humidifier valve o-ring. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .101 Trican sensor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103 Three way valve. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .104 Three-way valve connector. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105 Air filter cover. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106 Air box mounting bolts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .106 Fuse box bracket. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107 DI filter bracket. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107 Valve hose clamps. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .107 XV

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List of Figures Figure 145 146 147 148 149 150 151 152 153 154 155 156 157 158 159 160 161 162 163 164 165 166 167 168 169 170 171 172 173 174 175 176 177 178 179 180

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Page

Water level sensor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110 Disconnect batteries, fuel cell systems up to and including S/N A2D1S01500R. . . . . . . . . . . . . . 112 Disconnect batteries, fuel cell systems S/N A2D1S01501R and after. . . . . . . . . . . . . . . . . . . . . . . 112 Remove/Install overflow reservoir. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113 CVM connectors. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113 Battery terminals. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .113 Busbar. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113 Extension tool. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114 Loosen screws with extension tool. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114 Attach lifting eyes to fuel cell stack. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114 Remove stack. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114 Torquing sequence. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115 Tighten screws with extension tool. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115 Remove bottom bolts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .117 Remove top bolts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117 Remove hoses. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118 Replacing humidifier. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .118 Remove components. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118 Condenser O-rings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119 Replace thermocouples. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120 GEMS integrated sensor (old). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .121 US flying leads sensor (new). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121 Replace PS104 or PT157. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .122 Access panel. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124 Fuse box, fuel cell systems up to and including S/N A2D1S01500R. . . . . . . . . . . . . . . . . . . . . . . . .125 Fuse box,fuel cell systems S/N A2D1S01501R and after. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125 Fuses. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125 Relays, fuel cell systems up to and including S/N A2D1S01500R. . . . . . . . . . . . . . . . . . . . . . . . . . . 126 Access panel. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127 Relays, fuel cell systems S/N A2D1S01501R and after. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127 Battery terminals. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .128 Batteries, fuel cell systems up to and including S/N A2D1S01500R. . . . . . . . . . . . . . . . . . . . . . . . 129 Batteries, fuel cell systems S/N A2D1S01501R and after. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129 Battery label. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130 Depth of discharge vs. battery cell voltage. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131 XV154 and XV155, fuel cell systems up to and including S/N A2D1S01500R. . . . . . . . . . . . . . . . 133 XVI

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Nuvera® Fuel Cell System C95A-33 Service Manual

Contents

List of Figures Figure 181 182 183 184 185 186 187 188 189 190 191 192 193 194 195 196 197 198 199 200 201 202 203 204 205 206 207 208 209 210 211 212 213 214 215

Title

Page

XV155, fuel cell systems S/N A2D1S01501R and after. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133 Removing fuel line from ejector fitting, fuel cell systems up to and including S/N A2D1S01500R. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135 Removing fuel line from ejector fitting, fuel cell systems S/N A2D1S01501R and after. . . . . . . 135 Insulation, fuel cell systems up to and including S/N A2D1S01500R. . . . . . . . . . . . . . . . . . . . . . . .136 Insulation, fuel cell systems S/N A2D1S01501R and after. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .136 Removing manifold, fuel cell systems up to and including S/N A2D1S01500R. . . . . . . . . . . . . . . 136 Removing manifold, fuel cell systems S/N A2D1S01501R and after. . . . . . . . . . . . . . . . . . . . . . . . 136 Removing the ejector, fuel cell systems up to and including S/N A2D1S01500R. . . . . . . . . . . . . 137 Removing the ejector, fuel cell systems S/N A2D1S01501R and after. . . . . . . . . . . . . . . . . . . . . . 137 Removing hardware from ejector. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 137 Apply grease to ejector hardware. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 138 Bolt torque pattern. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 138 Buss bars, fuel cell systems up to and including S/N A2D1S01500R. . . . . . . . . . . . . . . . . . . . . . . . 141 Buss bars, fuel cell systems S/N A2D1S01501R and after. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 141 DC/DC bracket, fuel cell systems up to and including S/N A2D1S01500R. . . . . . . . . . . . . . . . . . . 142 DC/DC bracket, fuel cell systems S/N A2D1S01501R and after. . . . . . . . . . . . . . . . . . . . . . . . . . . . 142 Ultracapacitor module, fuel cell systems up to and including S/N A2D1S01500R. . . . . . . . . . . . 143 Ultracapacitor module, fuel cell systems S/N A2D1S01501R and after. . . . . . . . . . . . . . . . . . . . . 143 Battery leads. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 145 Top rear mounting bolt, fuel cell systems up to and including S/N A2D1S01500R. . . . . . . . . . . 146 Top rear mounting bolt, fuel cell systems S/N A2D1S01501R and after. . . . . . . . . . . . . . . . . . . . .146 DC/DC bracket, fuel cell systems up to and including S/N A2D1S01500R. . . . . . . . . . . . . . . . . . . 146 DC/DC bracket, fuel cell systems S/N A2D1S01501R and after. . . . . . . . . . . . . . . . . . . . . . . . . . . . 147 DC/DC unit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 147 Motor controller. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 150 Motor controller remove/install. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 150 Buss bars, fuel cell systems up to and including S/N A2D1S01500R. . . . . . . . . . . . . . . . . . . . . . . . 153 Buss bars, fuel cell systems S/N A2D1S01501R and after. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 153 Removing nuts from buss bar. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 153 CVM connectors. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 153 Removing the CVM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 154 VSM connectors. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 155 Removing the VSM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 156 Heater relay location. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 157 Remove heater relay. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 158 XVII

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Nuvera® Fuel Cell System C95A-33 Service Manual

Contents

List of Figures Figure 216 217 218 219 220 221 222 223 224 225 226 227 228 229 230

Title

Page

High pressure compartment panel. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 159 Fuel system, fuel cell systems up to and including S/N A2D1S01500R. . . . . . . . . . . . . . . . . . . . . . 160 Fuel system, fuel cell systems S/N A2D1S01501R and after. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 160 High pressure compartment access panel. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 162 Remove/install regulator, fuel cell systems up to and including S/N A2D1S01500R. . . . . . . . . . 163 Remove/install regulator, fuel cell systems S/N A2D1S01501R and after. . . . . . . . . . . . . . . . . . . 163 High pressure compartment access panel. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 165 Remove/install regulator, fuel cell systems up to and including S/N A2D1S01500R. . . . . . . . . . 166 Remove/install regulator, fuel cell systems S/N A2D1S01501R and after. . . . . . . . . . . . . . . . . . . 166 Remove Vent OK timer. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .168 Watchdog timer. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .168 Service panel. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 170 Remove timer. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 170 Watchdog timer setting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 171 Vent OK timer setting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 171

XVIII

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Nuvera® Fuel Cell System C95A-33 Service Manual

General Information

Safety information The following safety precautions must be observed at all times when servicing the Nuvera® Fuel Cell System. All maintenance should be performed by an authorized service provider or a Nuvera Fuel Cells LLC. representative.

NOTE: The following symbols and terms indicate safety information in this manual:

DANGER Indicates a hazardous situation where an immediate hazard presents a threat of death or serious injury.

WARNING Indicates a hazardous situation that, if not avoided, could result in death or serious injury.

CAUTION Indicates a potentially hazardous situation that, if not avoided, could result in minor or moderate injury or property damage.

NOTICE Used to address practices not related to physical injury.

SAFETY INSTRUCTIONS

Indication of specific safety-related instructions or procedures.

Personal Protective Equipment (PPE) The following PPE with arc-flash protection must be worn while performing certain procedures in the service manual: • • • •

Field Service Uniforms Face shield Gloves (rubber and leather) Steel toe shoes

1

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Nuvera® Fuel Cell System C95A-33 Service Manual

General Information

General hazards, warnings, and cautionary statements 1.

2.

shut down the system IMMEDIATELY if it is safe to do so.

Read this manual and other relevant documentation in its entirety before servicing this equipment. This manual provides specific guidelines for proper servicing of the Nuvera® Fuel Cell System.

Ensure that all service technicians are trained in the proper use of these systems. Provide all service technicians with a copy of this manual for reference before servicing the system.

9.

Do not service in any hazardous (classified) area other than while refueling.

11. Do not use the hydrogen fuel vessels ("tanks") past their expiration dates. The expiration dates are located on the nameplate.

12. Do not spray or power wash fuel cell system with any liquids.

There are hot surfaces, rotating parts, and hazardous electrical equipment inside the enclosure that could cause burns, cuts, and other injuries. Do not service if any covers are loose or missing.

4.

Disconnecting the main power connector will remove power from the truck. However, this will not act as emergency stop or de-energize the fuel cell system.

10. For indoor use only. Not rated for high humidity, wet, or rainy conditions.

CAUTION

3.

8.

13. The fuel cell system is not rated for use below -4°F (-20° C) or above 113°F (45°C). Do not store or leave unattended in freezer.

Before operation, make sure that all guards and covers are in place. Perform a daily inspection of the system to eliminate unwanted material that can hinder operation of the system or create a hazardous situation.

All maintenance should be performed by an authorized service provider. Unauthorized maintenance or repairs without proper certifications and training could result in a hazardous situation. Unauthorized maintenance or repairs may also void all warranties on the system.

WARNING The fuel cell system uses oxygen from the area in which it is being used. The fuel cell system should not be used in areas of tight construction with inadequate air ventilation.

14. Use only with NFPA Type E or Type CGH industrial electric trucks.

5.

Before servicing the equipment, familiarize yourself with the system and its controls.

6.

If the fuel cell system appears unsafe to operate for any reason, shut the system down and contact Nuvera.

7.

If a hazardous situation is discovered with the fuel cell system, such as an external or internal fire or large escape of flammable gas, 2

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Nuvera® Fuel Cell System C95A-33 Service Manual

General Information

Hydrogen-specific concerns The Nuvera® Fuel Cell System uses compressed hydrogen gas as the primary energy carrier. As with any fuel, handle hydrogen with caution. When handled with due care, hydrogen poses no more hazard than other fuels such as natural gas, propane, or gasoline, but hydrogen has unique properties that operators must appreciate. Refer to the Safety Data Sheet (SDS) for hydrogen for more information.

DANGER Hydrogen gas is flammable. To reduce the risk of fire: • Eliminate all ignition sources.

• Do not place an ignition source within 25 feet of the dispenser, sequence panel, or supply tubing.

• Do not smoke within a 25 foot radius of the dispenser or associated equipment.

• Do not perform hot work (work that requires open flame) within 25 feet of the hydrogen equipment area or the dispenser.

For other safety concerns, see the following sections in the Fuel Cell System Operating Manual.

• Hydrogen safety • Other potential safety hazards

• Emergency response procedures

WARNING Hydrogen gas is odorless, colorless, and tasteless which makes it undetectable by human senses. Although non-toxic, it can displace the oxygen in air and cause asphyxiation. Do not use in an enclosed environment.

WARNING The Nuvera® Fuel Cell System contains hydrogen gas under high pressure. To reduce the risk of injury relieve the pressure before servicing.

3

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Nuvera® Fuel Cell System C95A-33 Service Manual

Swagelok® fitting procedures

Swagelok® procedures

NOTE: This list does not include tools required for additional service procedures. Check the procedures below for necessary tools.

Scope To instruct the fuel cell system technician on the use of Swagelok® connectors.

CAUTION Fittings may be highly pressurized and can be hazardous if not handled properly. Do not perform any procedure involving Swagelok® fittings without proper training and certification.

Safety and warnings NOTE: Do not perform this procedure unless you have fully read and understand this document.

1.

Read this manual and other specified documentation in their entirety before servicing this equipment.

2.

Before performing this procedure, ensure that you have the proper skill and specialty training needed to perform this procedure as it applies to both the Nuvera® Fuel Cell System and all supplemental equipment used. If you feel that you are not qualified to perform this procedure, contact Nuvera Fuel Cells LLC.

3.

Use caution when handling all parts in the fuel cell, as they may contain compressed hydrogen gas.

Initial seating 1.

Fully insert the tube into the fitting and against the shoulder. See Figure 1.

DANGER Hydrogen gas is flammable. Eliminate all ignition sources. Do not place an ignition source within 25 feet of this unit. DO NOT SMOKE WITHIN A 25 FOOT RADIUS OF THE FUEL CELL.

Figure 1. Insert tube into fitting

Tools required Nuvera part number

Description

Qty.

N/A

Swagelok® gap inspection tool

1

4

2.

Rotate the nut until finger-tight.

3.

Continue to tighten the nut until the tube will not turn by hand or move axially in the fitting.

4.

Mark the nut at the 6 o'clock position. See Figure 2.

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Nuvera® Fuel Cell System C95A-33 Service Manual

Swagelok® fitting procedures

Figure 2. 6 o'clock position 5.

Figure 4. Marking line

Hold the fitting body steady and tighten the nut one and one-quarter turns to the 9 o'clock position. See Figure 3.

7.

For 1/16, 1/8, and 3/16 in., tighten the nut three-quarters turn to the 3 o'clock position.

Figure 3. 9 o'clock position 6.

On initial inspection, the Swagelok® gap inspection gauge assures the installer or inspector that a fitting has been sufficiently tightened. Position the Swagelok® gap inspection gauge next to the gap between the nut and body. See Figure 5.

Figure 5. Gap inspection

Mark the tube at the back of the nut and mark a line across the nut and fitting body flats. See Figure 4.

8.

5

If the guage will not enter the gap, the fitting is sufficiently tightened. If the guage will enter the gap, additional tightening is required.

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Nuvera® Fuel Cell System C95A-33 Service Manual

Swagelok® fitting procedures

Disassembly and reseating NOTE: Always depressurize the system before disassembling a Swagelok® tube fitting.

1.

Prior to disassembly. mark the tube at the back of the nut; mark a line along the nut and fitting body flats. Use these marks to ensure that previously pulled-up position. See Figure 6.

2.

Insert the tube with pre-swaged ferrules into the fitting until the front ferrule seats.

3.

While holding the fitting body steady, rotate the nut with a wrench to the pulled-up position, as indicated by the marks on the tube and flats. You will feel a significant increase in resistance. Tighten the nut slightly.

4.

Remove the previous markings.

NOTE: Do not use the Swagelok® gap inspection gauge with reassembled fittings.

5.

Re-Mark the tube at the back of the nut and mark a line across the nut and fitting body flats. Always check assembled fittings under pressure with Snoop® for leaks.

Figure 6. Marking line

6

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Nuvera® Fuel Cell System C95A-33 Service Manual

Preparing for service and maintenance

Components of the Nuvera® fuel cell system

Figure 7. Internal fuel cell components 1.

LIFTING EYES

7.

THERMAL MANAGEMENT

2.

HYBRID POWER SYSTEM

8.

FUEL CELL COMPONENTS

3.

POWER ELECTRONICS

9.

FUEL CELL STACK SUB-SYSTEM

4.

BATTERY CONNECTOR

10.

MAIN COVER

5.

HIGH PRESSURE COMPARTMENT (HYDROGEN STORAGE)

11.

AIR FILTER ACCESS PANEL

6.

HIGH PRESSURE COMPARTMENT ACCESS PANEL

7

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Nuvera® Fuel Cell System C95A-33 Service Manual

Preparing for service and maintenance

Warning labels

Figure 8. These warning labels will be found on the Nuvera® Fuel Cell System

8

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Nuvera® Fuel Cell System C95A-33 Service Manual

Preparing for service and maintenance

Required procedures prior to service

Scope Before attempting any service or maintenance task on the Nuvera® Fuel Cell System, the following procedures may need to be performed: • Preparing the truck and removing the fuel cell • Preparing the Nuvera fuel cell system for service • Opening and closing storage tank valves • Discharging and recharging the ultracapacitors • Working with charged ultracapacitors with cover removed1

___________________________

1 This procedure is not required and is only to be performed in certain situations with special equipment and training, as

indicated by a service or troubleshooting procedure.

9

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Nuvera® Fuel Cell System C95A-33 Service Manual

Preparing for service and maintenance

Secure the truck

Preparing the truck and removing the fuel cell

Scope To prepare the truck for Fuel Cell System removal.

Safety and warnings

1.

Move the truck to a well-ventilated area approved for servicing.

2.

Shut down the truck.

3.

Confirm the key is in the OFF position.

4.

Press STOP button on the truck user interface display to initiate normal shutdown sequence of FCS. This process will take about one minute.

NOTE: Do not perform this procedure unless you have fully read and understand this document.

1.

Read this manual and other specified documentation in their entirety before servicing this equipment.

2.

Before performing this procedure, ensure that you have the proper skill and specialty training needed to perform this procedure as it applies to both the Nuvera® Fuel Cell System and all supplemental equipment used. If you feel that you are not qualified to perform this procedure, contact Nuvera Fuel Cells LLC.

3.

Prepare the truck

Use caution when handling all parts in the fuel cell, as they may contain compressed hydrogen gas.

1.

Press truck E-Stop to ensure FCS is fully deenergized.

2.

Disconnect power cable connector and FCS auxiliary connector J2.

3.

Measure voltage at the power cable connector to ensure the fuel cell is not supplying power even with E-Stop engaged. If voltage is > 0.5V do not proceed. Contact your service provider.

DANGER Hydrogen gas is flammable. Eliminate all ignition sources. Do not place an ignition source within 25 feet of this unit. DO NOT SMOKE WITHIN A 25 FOOT RADIUS OF THE FUEL CELL.

Tools required Nuvera part number

Description

Qty.

N/A

Multimeter

1

Figure 9. Measure connector with multimeter

Remove the Fuel Cell System

NOTE: This list does not include tools required for additional service. Check the procedures below for necessary tools.

10

To remove the Fuel Cell System, see Nuvera® Fuel Cell System-Installation manual.

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Nuvera® Fuel Cell System C95A-33 Service Manual

Preparing for service and maintenance

Preparing the Nuvera fuel cell system for service

Scope To prepare the fuel cell to be serviced or for maintenance procedures to be performed.

Nuvera part number

Description

Qty.

N/A

Needle nose pliers

1

NOTE: This list does not include tools required for additional service procedures. Check the procedures below for necessary tools.

Safety and warnings NOTE: Do not perform this procedure unless you have fully read and understand this document.

1.

Read this manual and other specified documentation in their entirety before servicing this equipment.

2.

Before performing this procedure, ensure that you have the proper skill and specialty training needed to perform this procedure as it applies to both the Nuvera® Fuel Cell System and all supplemental equipment used. If you feel that you are not qualified to perform this procedure, contact Nuvera Fuel Cells LLC.

3.

WARNING Removing the air filter/fuse box access panel introduces a potential hazard due to exposure of rotating fan. To avoid injury, keep hands away from the fan.

Remove the air filter access panel 1.

Locate air filter access panel on the fuel cell.

Use caution when handling all parts in the fuel cell, as they may contain compressed hydrogen gas.

DANGER Hydrogen gas is flammable. Eliminate all ignition sources. Do not place an ignition source within 25 feet of this unit. DO NOT SMOKE WITHIN A 25 FOOT RADIUS OF THE FUEL CELL.

Tools required Nuvera part number

Description

N/A

Hex head wrench

Qty. Figure 10. Air filter access panel

1 set

11

1.

CAPSCREW

2.

AIR FILTER ACCESS PANEL

3.

LOW PRESSURE COMPARTMENT

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Nuvera® Fuel Cell System C95A-33 Service Manual

Preparing for service and maintenance

2.

Use a hex head wrench to remove the 7 capscrews fastening the air filter access panel to the fuel cell.

3.

Place the removed hardware in a magnetic bowl or similar receptacle, to keep it from falling or dropping into the fuel cell.

WARNING Do not remove the access panel over the ultracapacitors, to avoid exposure to high voltage/power connections.

4.

Remove the air filter access panel. See Figure 10.

5.

Use needle nose pliers to remove all fuses and relays needed for probing or troubleshooting, if necessary. This will minimize the opportunity for dropping components and damaging terminals.

Install the air filter access panel Once maintenance is complete, the air filter access panel may be reinstalled.

1.

Install the air filter access panel on the fuel cell. See Figure 10.

2.

Install the 7 capscrews fastening the access panel to the fuel cell. See Figure 10.

3.

Use a hex head wrench to tighten the capscrews to 19.4 N•m (14.3 lbf ft.).

12

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Preparing for service and maintenance

Discharging and recharging the ultracapacitors

Nuvera part number

Description

Qty.

To remove power from the ultracapacitors, prior to service and maintenance.

N/A

CAN-to-USB adapter (LeafLight v2.0 or similar)

1

Safety and warnings

N/A

IFAK cable

1

N/A

Load bank

N/A

Scope

NOTE: Do not perform this procedure unless you have fully read and understand this document.

1.

Read this manual and other specified documentation in their entirety before servicing this equipment.

2.

Before performing this procedure, ensure that you have the proper skill and specialty training needed to perform this procedure as it applies to both the Nuvera® Fuel Cell System and all supplemental equipment used. If you feel that you are not qualified to perform this procedure, contact Nuvera Fuel Cells LLC.

3.

NOTE: This list does not include tools required for additional service. Check the procedures below for necessary tools.

Discharge the ultracapacitors 1.

Connect the portable, externally powered load bank to the Anderson connector on the fuel cell system.

Use caution when handling all parts in the fuel cell, as they may contain compressed hydrogen gas.

DANGER Hydrogen gas is flammable. Eliminate all ignition sources. Do not place an ignition source within 25 feet of this unit. DO NOT SMOKE WITHIN A 25 FOOT RADIUS OF THE FUEL CELL.

Tools required Figure 11. Connect fuel cell to external load bank Nuvera part number

Description

Qty.

N/A

Laptop with Nuvera® FCS Service Tool installed

1

2.

Turn load bank control electronics on (if applicable), but do not enable the load yet.

3.

From the FCS Service Tool Menu Bar: • Select Service > Prepare to Charge or Discharge Ultracaps. See Figure 12.

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Preparing for service and maintenance

Recharge the ultracapacitors 1.

Use the load bank to perform the following steps:

Engine Class

Power Supply Voltage Setpoint

Class I

56V

Class II

42V

2.

Turn off power supply.

3.

Confirm fuel cell system is off.

4.

Connect positive and negative leads from power supply to their respective lugs on the fuel cell system Anderson connector (main load connector).

5.

From the FCS Service Tool Menu Bar:

Figure 12. Charge Ultracaps 4.

Turn on variable voltage power supply (not yet connected to anything), confirm it is set to 15A output current and the appropriate output voltage for the engine class:

• Select Service > Prepare to Charge or Discharge Ultracaps. See Figure 13.

a.

Enable load at 50A draw.

b.

Increase load to 150A in increments of 50A.

c.

When ultracap voltage has decreased to ≤ 1V, set load to 0A then disable the load.

NOTE: If the load bank does not allow voltage to reach ≤ 1V, an automotive battery tester may be used.

5.

Select the button on the service tool window to complete discharge. System will shut off.

6.

Disconnect the Anderson connector between fuel cell and load bank.

Figure 13. Discharge Ultracaps 14

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Nuvera® Fuel Cell System C95A-33 Service Manual

Preparing for service and maintenance

6.

Turn the power supply back on. a.

Displayed current should be ~15A.

b.

Displayed voltage should start low (matching Ultracap voltage) and begin to climb slowly as the ultracapacitors accumulate charge.

7.

Once the displayed voltage reaches the power supply voltage setpoint (± 1V) and the current drops to 2-3 amps, turn the power supply back off.

8.

Select the button on the service tool window to complete charge. System will shut off.

9.

Disconnect the power supply leads from the Anderson connector.

15

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Preparing for service and maintenance

Removing and installing the main cover

Scope To remove the main cover on the Nuvera® Fuel Cell System prior to service and maintenance.

Nuvera part number

Description

Qty.

N/A

Hoist (engine hoist or overhead crane hoist)

1

N/A

Laptop with GUI installed

1

Safety and warnings NOTE: Do not perform this procedure unless you have fully read and understand this document.

1.

Read this manual and other specified documentation in their entirety before servicing this equipment.

2.

Before performing this procedure, ensure that you have the proper skill and specialty training needed to perform this procedure as it applies to both the Nuvera® Fuel Cell System and all supplemental equipment used. If you feel that you are not qualified to perform this procedure, contact Nuvera Fuel Cells LLC.

3.

Discharge ultracapacitors

WARNING Working with charged ultracapacitors can be hazardous. To reduce the risk of arc-flash and electric shock, remove power from the ultracapacitors before proceeding.

Use caution when handling all parts in the fuel cell, as they may contain compressed hydrogen gas.

Before removing the main cover, make sure that the charge on the ultracapacitors is ˂5V. See Discharging and recharging the ultracapacitors prior to removing the main cover.

DANGER Hydrogen gas is flammable. Eliminate all ignition sources. Do not place an ignition source within 25 feet of this unit. DO NOT SMOKE WITHIN A 25 FOOT RADIUS OF THE FUEL CELL.

Remove main cover 1.

Tools required Nuvera part number

Description

Qty.

N/A

5 mm hex head wrench

1

NOTE: This list does not include tools required for additional service. Check the procedures below for necessary tools.

Before installing the lifting eye on main cover, insert the bolt that secures the center of the lifting eye into the hole on the main cover and thread the bolt just enough to confirm a tight fit. If the bolt does not fit securely or there is evidence that the nut underneath the main cover has been stripped, please remove the cover and discard the entire lifting eye plate. Replace with new. See Remove and replace lifting eye plate.

NOTE: Always use Nuvera approved and ANSI rated lifting eyes, clamps, bolts, and chains.

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2.

Inspect the lifting eyes. Replace the lifting eyes if: • The lifting eye appears cracked • The lifting eye is bent • The lifting eye doesn't swivel

3.

On the low pressure compartment side, insert the bolt through the center of the lifting eye and attach to the main cover (see Figure 14). Use 10 mm hex-bit socket, to tighten bolt to 38 N•m (24 lbf ft.).

Figure 15. Attach lifting chain to main cover NOTE: LIFTING EYES SHOWN MAY NOT REFLECT THE LIFTING EYES CURRENTLY INSTALLED ON THE FUEL CELL SYSTEM. 7.

Use the 5 mm hex head wrench to remove the capscrews from the upper lip, lower lip, and the two corners. See Figure 16.

Figure 14. Lifting eyes: Low pressure compartment 1.

BOLT

3.

MAIN COVER

2.

LIFTING EYE

4.

LOW PRESSURE COMPARTMENT

4.

Connect D-clamps, S-hook, or similar clip rated for cover weight of 50 kg. (110.2 lbs) to the two lifting eyes on the cover. See Figure 15.

5.

Connect a lifting chain, cable, or wire rope rated for cover weight between D-clamps.

See Figure 15.

6.

Figure 16. Remove/Install main cover

Connect an overhead crane hoist or engine hoist to the lifting chain, cable, or wire rope.

17

1.

MAIN COVER LOWER LIP

4.

MAIN COVER UPPER LIP

2.

CAPSCREW

5.

BOLT

3.

LOW PRESSURE COMPARTMENT

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Nuvera® Fuel Cell System C95A-33 Service Manual

Preparing for service and maintenance

8.

Slowly lift cover upward a short distance, just enough to disengage cover from the fuel cell.

1.

CAUTION

With the main cover removed, locate the four capscrews attaching the lifting eye plate to the underside of the main cover. See Figure 17.

The main cover weight is uneven which may cause the main cover to hang offcenter when lifted. To reduce the risk of injury or damage to the fuel cell, remove the cover slowly to keep from swinging.

9.

Roll hoist away from the fuel cell and lower the cover to the ground.

Install main cover 1.

Connect D-clamps, S-hook, or similar clip rated for cover weight of 50 kg. (110.2 lbs), to the two lifting eyes on the cover. See Figure 15.

2.

Connect a lifting chain, cable, or wire rope rated for cover weight between D-clamps.

See Figure 15.

3.

Connect an overhead crane hoist or engine hoist to the lifting chain, cable, or wire rope.

Figure 17. Lifting eyes: Low pressure compartment 1.

BOLT

4.

LIFTING EYE PLATE

Roll hoist toward fuel cell, and slowly lower the cover on to the fuel cell, taking care to not touch any components other than the exterior of the fuel cell enclosure.

2.

LIFTING EYE

5.

CAPSCREW

3.

MAIN COVER

6.

LOW PRESSURE COMPARTMENT

5.

Insert the capscrews into the main cover to secure cover to the fuel cell. See Figure 16.

2.

Use the 5 mm hex-bit socket, to loosen the capscrews.

6.

Use the 5 mm hex head wrench to tighten the capscrews to 47.2 N•m (34.8 lbf ft.).

3.

Remove the lifting eye plate and discard.

Replace with new.

4.

Replace capscrews and tighten to 38 N•m (24 lbf ft.).

4.

Remove and replace lifting eye plate NOTE: The following procedures (Step 1. and Step 4.) are for one lifting eye. There are two lifting eye plates under the main cover on the low pressure compartment side of the fuel cell.

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Preparing for service and maintenance

Working with charged ultracapacitors with cover removed

Scope To prepare the Fuel Cell System for service and maintenance while the cover is off and ultracapacitors are charged.

Safety and warnings NOTE: Do not perform this procedure unless you have fully read and understand this document.

1.

Read this manual and other specified documentation in their entirety before servicing this equipment.

2.

Before performing this procedure, ensure that you have the proper skill and specialty training needed to perform this procedure as it applies to both the Nuvera® Fuel Cell System and all supplemental equipment used. If you feel that you are not qualified to perform this procedure, contact Nuvera Fuel Cells LLC.

3.

Use caution when handling all parts in the fuel cell, as they may contain compressed hydrogen gas.

Nuvera part number

Description

Qty.

N/A

Hoist (engine picker or overhead crane)

1

N/A

Personal Protective Equipment (See below)

N/A

025992-01

Plexiglas® cap bank cover

1

DANGER Hydrogen gas is flammable. Eliminate all ignition sources. Do not place an ignition source within 25 feet of this unit. DO NOT SMOKE WITHIN A 25 FOOT RADIUS OF THE FUEL CELL.

Tools required Nuvera part number

Description

Qty.

N/A

Hex head keys

1 set

19

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Nuvera® Fuel Cell System C95A-33 Service Manual

Preparing for service and maintenance

NOTE: This list does not include tools required for additional service procedures. Check the procedures below for necessary tools.

Personal Protective Equipment (PPE) 1.

WARNING The fuel cell enclosure contains rotating fans and equipment. To avoid injury, keep hands clear of moving fans.

Use arc flash PPE category 2 or higher in accordance with NFPA 70E while performing this procedure. Category 2 PPE is listed in Table 130.7©)(16) of NFPA 70E: 2015 and includes but is not limited to the following: • • • • •

WARNING The fuel cell enclosure contains internal components such as the cooling system and manifolds that can reach 75°C (167°F). To prevent burns, use caution while working near these items.

Field Service Uniforms Face shield Gloves (rubber and leather) Steel toe shoes Arc-flash suit, if Field Service Uniform is not available.

Remove main cover If the cover must be removed while fuel cell is operational, use caution and remove cover very slowly, so as not to make contact with charged ultracapacitors. See Remove main cover for procedure. Install the protective Plexiglas cover over the cap bank.

WARNING The ultracapacitors remain charged even when the fuel cell power system is off and can be an electric shock hazard due to the voltage and an arc flash hazard due to the prospective shortcircuit current and a thermal hazard.

Whenever possible discharge the ultracapacitors before opening the covers. If this is not possible, use the Personal Protective Equipment (PPE) noted below. The ultracapacitors have an incident energy of 6 cal./cm2. The associated arc flash boundary is 130 cm (51 inches) per NFPA 70E.

Working with charged ultracapacitors 1.

The metallic surfaces of the fast-on connectors will carry +24VDC when the system is powered on. Ensure that they are safely located, isolated and insulated, by wrapping with electrical tape or similar.

2.

Apply a tag, using a piece of tape to the top side of the fuel cell system, over the high pressure compartment stating “DPS jumped out”.

3.

Test or troubleshoot as necessary.

4.

Disconnect fast-on connectors and return to DPS terminals.

5.

Remove tag indicating DPS jumped out.

Procedure Occasionally, performing a diagnostic troubleshooting procedure will require the fuel cell to be running and ultracapacitors to be charged. In this event, the service technician must be aware of arc flash potential and must use proper PPE with arc flash protection.

The procedure below must only be performed by certified personnel, according to NFPA 70 E. 20

NOTE: Occasionally the tubes may become dislodged during shipping or operation, causing the DPS to fault. Adjust the tubes to the proper position to ensure an accurate pressure reading. www.nuvera.com

Nuvera® Fuel Cell System C95A-33 Service Manual

Preparing for service and maintenance

6.

Reinstall cover. See Remove main cover.

21

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Nuvera® Fuel Cell System C95A-33 Service Manual

Preparing for service and maintenance

Start into off mode

NOTE: This list does not include tools required for additional service procedures. Check the procedures below for necessary tools.

Safety and warnings NOTE: Do not perform this procedure unless you have fully read and understand this document.

1.

Read this manual and other specified documentation in their entirety before servicing this equipment.

2.

Before performing this procedure, ensure that you have the proper skill and specialty training needed to perform this procedure as it applies to both the Nuvera® Fuel Cell System and all supplemental equipment used. If you feel that you are not qualified to perform this procedure, contact Nuvera Fuel Cells LLC.

3.

Use caution when handling all parts in the fuel cell, as they may contain compressed hydrogen gas.

Start into off mode 1.

From the FCS Service Tool Menu Bar: • Select Service > Start system into "Off" mode.

DANGER Hydrogen gas is flammable. Eliminate all ignition sources. Do not place an ignition source within 25 feet of this unit. DO NOT SMOKE WITHIN A 25 FOOT RADIUS OF THE FUEL CELL.

Figure 18. Start system into Off mode

Tools required

2.

Nuvera part number

Description

Qty.

N/A

Laptop with Nuvera® FCS Service Tool installed

1

N/A

CAN-to-USB adapter (LeafLight v2.0 or similar)

1

N/A

IFAK cable

1

22

A new window will appear with the next step.

Follow the instructions on the prompt:

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Nuvera® Fuel Cell System C95A-33 Service Manual

Preparing for service and maintenance

Figure 19. System is in 'off' mode 3.

The indicator window will turn green to signal the system is in OFF mode. See Figure 19

4.

Click OK.

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Preparing for service and maintenance

Leak check coolant loop

Safety and warnings NOTE: Do not perform this procedure unless you have fully read and understand this document.

Nuvera part number

Description

Qty.

N/A

HY standard diagnostic cable (3 pin Deutsch to DB9)

1

1

1.

Read this manual and other specified documentation in their entirety before servicing this equipment.

2.

Before performing this procedure, ensure that you have the proper skill and specialty training needed to perform this procedure as it applies to both the Nuvera® Fuel Cell System and all supplemental equipment used. If you feel that you are not qualified to perform this procedure, contact Nuvera Fuel Cells LLC.

N/A

Variable voltage power supply

N/A

Nitrogen bottle with 25 psi output via 1/4" stainless steel tubing

1

Use caution when handling all parts in the fuel cell, as they may contain compressed hydrogen gas.

N/A

Flexible rubber tubing

AR

3.

NOTE: This list does not include tools required for additional service procedures. Check the procedures below for necessary tools.

DANGER Hydrogen gas is flammable. Eliminate all ignition sources. Do not place an ignition source within 25 feet of this unit. DO NOT SMOKE WITHIN A 25 FOOT RADIUS OF THE FUEL CELL.

Leak check coolant loop Draining coolant 1.

See Set up for external supply of nominal bus voltage and follow all steps.

2.

Turn on power supply and ensure that the output voltage is still correct per the table in Set up for external supply of nominal bus voltage.

3.

From the FCS Service Tool Menu Bar:

Tools required Nuvera part number

Description

Qty.

N/A

Laptop with Nuvera® FCS Service Tool installed

1

CAN-to-USB adapter (LeafLight v2.0 or similar)

1

N/A

• Select Service > Coolant Loop Leak Check.

24

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Nuvera® Fuel Cell System C95A-33 Service Manual

Preparing for service and maintenance

Figure 20. Coolant Loop Leak Check 4.

A new window will appear, detailing the next step. Follow the instructions on the prompt to Start into off mode.

5.

Disconnect overflow tube from radiator side.

6.

Connect nitrogen tank to radiator via flexible tubing at the overflow port.

7.

Dial nitrogen regulator all the way out.

8.

Open nitrogen tank. Dial in regulator until 10 psi outlet is reached.

9.

Close nitrogen tank. Monitor regulator outlet pressure to ensure pressure is maintained.

10. If leak rate is ≤ 1psi/minute, leak check has passed. If leak rate is ≥ 1psi/minute, locate and repair leak, then repeat from Step 3. before proceeding to next step.

Filling coolant 1.

Reinstall overflow tube.

2.

Disconnect nitrogen tank from radiator.

3.

See Revert to normal ultracaps connection and follow all steps.

25

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Preparing for service and maintenance

Leak check anode loop

Safety and warnings NOTE: Do not perform this procedure unless you have fully read and understand this document.

Nuvera part number

Description

Qty.

N/A

HY standard diagnostic cable (3 pin Deutsch to DB9)

1

1

1.

Read this manual and other specified documentation in their entirety before servicing this equipment.

2.

Before performing this procedure, ensure that you have the proper skill and specialty training needed to perform this procedure as it applies to both the Nuvera® Fuel Cell System and all supplemental equipment used. If you feel that you are not qualified to perform this procedure, contact Nuvera Fuel Cells LLC.

N/A

Variable voltage power supply

N/A

Nitrogen bottle with 25 psi output via 1/4" stainless steel tubing

1

Use caution when handling all parts in the fuel cell, as they may contain compressed hydrogen gas.

N/A

Flexible rubber tubing

AR

3.

NOTE: This list does not include tools required for additional service procedures. Check the procedures below for necessary tools.

DANGER Hydrogen gas is flammable. Eliminate all ignition sources. Do not place an ignition source within 25 feet of this unit. DO NOT SMOKE WITHIN A 25 FOOT RADIUS OF THE FUEL CELL.

Leak check anode loop

Tools required Nuvera part number

Description

N/A

Laptop with Nuvera® FCS Service Tool installed

1

N/A

CAN-to-USB adapter (LeafLight v2.0 or similar)

1

1.

See Set up for external supply of nominal bus voltage and follow all steps.

2.

Turn on power supply and ensure that the output voltage is still correct per the table in Set up for external supply of nominal bus voltage.

3.

From the FCS Service Tool Menu Bar:

Qty.

• Select Service > Anode Loop Leak Check.

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Preparing for service and maintenance

Figure 21. Anode Loop Leak Check 4.

A new window will appear, detailing the next step. Follow the instructions on the prompt to Start into off mode.

5.

Follow all prompts and ensure procedure completes successfully.

6.

If either of the following prompts are displayed when running the anode loop leak check, a leak has been detected. The leak must be corrected and the procedure re-run to confirm the test has completed successfully before returning the fuel cell system to service.

7.

27

See Revert to normal ultracaps connection and follow all steps.

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Nuvera® Fuel Cell System C95A-33 Service Manual

Preparing for service and maintenance

Leak check H2 plumbing

Safety and warnings NOTE: Do not perform this procedure unless you have fully read and understand this document.

1.

Read this manual and other specified documentation in their entirety before servicing this equipment.

2.

Before performing this procedure, ensure that you have the proper skill and specialty training needed to perform this procedure as it applies to both the Nuvera® Fuel Cell System and all supplemental equipment used. If you feel that you are not qualified to perform this procedure, contact Nuvera Fuel Cells LLC.

3.

Nuvera part number

Description

Qty.

N/A

HY standard diagnostic cable (3 pin Deutsch to DB9)

1

N/A

Variable voltage power supply

1

N/A

Snoop™ leak detector

AR

NOTE: This list does not include tools required for additional service procedures. Check the procedures below for necessary tools.

Use caution when handling all parts in the fuel cell, as they may contain compressed hydrogen gas.

Pressurize H2 Plumbing via Nuvera® Fuel Cell System Service Tool 1.

DANGER Hydrogen gas is flammable. Eliminate all ignition sources. Do not place an ignition source within 25 feet of this unit. DO NOT SMOKE WITHIN A 25 FOOT RADIUS OF THE FUEL CELL.

Select Service > Pressurize H2 Plumbing for Manual Leak Check.

Tools required Nuvera part number

Description

Qty.

N/A

Laptop with Nuvera® FCS Service Tool installed

1

N/A

CAN-to-USB adapter (LeafLight v2.0 or similar)

1

Figure 22. Pressurize H2 plumbing 28

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Nuvera® Fuel Cell System C95A-33 Service Manual

Preparing for service and maintenance

A new window will appear (see Figure 23).

Click OK to complete the procedure. Use Snoop™ to confirm the hydrogen plumbing in the high pressure compartment is leak-free.

Figure 23. Pressurize H2 prompt • Another window will appear confirming the procedure has succesfully completed.

Click OK. • If the procedure cannot be completed successfully within three attempts, contact Nuvera for assistance.

2.

If the unit is still running, select Shut Down the System.

3.

If the procedure cannot be completed successfully within three attempts, contact HYG representative.

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Nuvera® Fuel Cell System C95A-33 Service Manual

Preparing for service and maintenance

Vent hydrogen from engine plumbing lines

3.

Use caution when handling all parts in the fuel cell, as they may contain compressed hydrogen gas.

NOTICE

DANGER

Ensure venting is performed in a room with enough ventilation. This procedure only vents hydrogen plumbing lines, it does not vent hydrogen tank pressure.

Hydrogen gas is flammable. Eliminate all ignition sources. Do not place an ignition source within 25 feet of this unit. DO NOT SMOKE WITHIN A 25 FOOT RADIUS OF THE FUEL CELL.

NOTE: Perform this procedure prior to anytime a hydrogen line or fitting is removed for service.

WARNING

Safety and warnings NOTE: Do not perform this procedure unless you have fully read and understand this document.

1.

Read this manual and other specified documentation in their entirety before servicing this equipment.

2.

Before performing this procedure, ensure that you have the proper skill and specialty training needed to perform this procedure as it applies to both the Nuvera® Fuel Cell System and all supplemental equipment used. If you feel that you are not qualified to perform this procedure, contact Nuvera Fuel Cells LLC.

The unit may contain pressurized hydrogen. Pressurized gases can cause pressure injection injuries and can propel small particles at high velocity. In addition, hydrogen becomes flammable when mixed with air. Only connect to a vent line suitable for hydrogen to reduce the chance of fire or explosion.

Refer to NFPA 2 and CGA G-5.5 for hydrogen vent requirements.

Tools required

30

Nuvera part number

Description

Qty.

N/A

Laptop with Nuvera® FCS Service Tool installed

1

31004844

IFak or Kvaser CAN reader adapter

1

1534009

HY orange 3 pin diagnostic cable

1

N/A

Variable voltage power supply

1

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Nuvera® Fuel Cell System C95A-33 Service Manual

Preparing for service and maintenance

Nuvera part number

Description

Qty.

N/A

Flexible rubber tubing

AR

NOTE: This list does not include tools required for additional service procedures. Check the procedures below for necessary tools.

1.

From the FCS Service Tool Menu Bar: • Select Service > Vent H2 from Plumbing Lines.

Figure 24. Vent Hydrogen from Plumbing Lines 2.

A new window will appear, detailing the next step. Follow the instructions on the prompt: • Press START while holding STOP button until Fuel Cell State reads OFF.

3.

Follow all prompts and ensure procedure completes successfully.

4.

System will shut off.

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Set up for external supply of nominal bus voltage

NOTE: This list does not include tools required for additional service procedures. Check the procedures below for necessary tools.

Safety and warnings NOTE: Do not perform this procedure unless you have fully read and understand this document.

1.

Read this manual and other specified documentation in their entirety before servicing this equipment.

2.

Before performing this procedure, ensure that you have the proper skill and specialty training needed to perform this procedure as it applies to both the Nuvera® Fuel Cell System and all supplemental equipment used. If you feel that you are not qualified to perform this procedure, contact Nuvera Fuel Cells LLC.

3.

Use caution when handling all parts in the fuel cell, as they may contain compressed hydrogen gas.

1.

Confirm ultracapacitors are discharged. See Discharging and recharging the ultracapacitors

2.

Remove the main cover. See Removing and installing the main cover.

3.

Locate the 13 mm insulated wrench. See Figure 25.

DANGER Hydrogen gas is flammable. Eliminate all ignition sources. Do not place an ignition source within 25 feet of this unit. DO NOT SMOKE WITHIN A 25 FOOT RADIUS OF THE FUEL CELL.

Figure 25. 13 mm wrench

Tools required Nuvera part number

Description

Qty.

N/A

Variable voltage power supply

1

N/A

13 mm insulated wrench

1

32

4.

Use the wrench to disconnect positive (red) buss bar from ultracapacitor module.

5.

Apply electrical tape to the ultracapacitor module positive tab, to ensure the busbar cannot make incidental contact and introduce charge to the caps. See Figure 26.

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Engine Class

Power Supply Voltage Setpoint

Class I

48V

Class II

36V

7.

Turn off power supply and wait for it to power off.

8.

Connect power supply’s positive lead to the positive (red) busbar that was removed from the ultracapacitor module. Connect power supply’s negative lead to the negative (black) busbar that is still installed on the ultracapacitor module. See Figure 28.

Figure 26. Tape buss bar 6.

Turn on variable voltage power supply (not yet connected to anything). Confirm it is set to 15A output current and the appropriate output voltage for the engine class. See Figure 27.

Figure 28. Connect power supply leads

Figure 27. Power supply 33

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Revert to normal ultracaps connection

Safety and warnings NOTE: Do not perform this procedure unless you have fully read and understand this document.

1.

Read this manual and other specified documentation in their entirety before servicing this equipment.

2.

Before performing this procedure, ensure that you have the proper skill and specialty training needed to perform this procedure as it applies to both the Nuvera® Fuel Cell System and all supplemental equipment used. If you feel that you are not qualified to perform this procedure, contact Nuvera Fuel Cells LLC.

3.

Use caution when handling all parts in the fuel cell, as they may contain compressed hydrogen gas.

DANGER Hydrogen gas is flammable. Eliminate all ignition sources. Do not place an ignition source within 25 feet of this unit. DO NOT SMOKE WITHIN A 25 FOOT RADIUS OF THE FUEL CELL. 1.

Remove power supply leads from positive/ negative busbars.

2.

Remove tape from the ultracapacitor module positive tab.

3.

Use insulated tools to reinstall positive busbar on ultracapacitor positive tab.

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Installing Vector VN1610 drivers

• Scroll to the VN16xx line and select it. See Figure 29.

• Click on the red Show Results button.

Safety and warnings NOTE: Do not perform this procedure unless you have fully read and understand this document.

1.

Read this manual and other specified documentation in their entirety before servicing this equipment.

2.

Before performing this procedure, ensure that you have the proper skill and specialty training needed to perform this procedure as it applies to both the Nuvera® Fuel Cell System and all supplemental equipment used. If you feel that you are not qualified to perform this procedure, contact Nuvera Fuel Cells LLC.

3.

Use caution when handling all parts in the fuel cell, as they may contain compressed hydrogen gas.

Figure 29. Download software 2.

Select the check box for Driver/Firmware.

Click the red Continue button. See Figure 30.

DANGER Hydrogen gas is flammable. Eliminate all ignition sources. Do not place an ignition source within 25 feet of this unit. DO NOT SMOKE WITHIN A 25 FOOT RADIUS OF THE FUEL CELL.

Parts and materials required Nuvera part number

Description

Qty.

N/A

Laptop

1

Figure 30. Select Driver/Firmware 3.

Install

Select the line that reads Vector Driver Setup. See Figure 31.

NOTE: For more information on downloading Vector software , see Retrieving data from vector data-logger.

1.

To install the Vector software: • Go to Vector Download website (https:// vector.com/vi_downloadcenter_en.html).

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Figure 31. Setup 4.

Once download is finished, a zipped file will appear. Extract all files.

• Open the extracted folder.

• Click setup application.

5.

Check the VN1610 box and click the Install button.

Figure 32. Install 6.

Allow program to run until install is complete.

7.

Close the program. Drivers will be loaded.

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Retrieving data from vector data-logger

1.

• Locate the CD that comes in the box with the new GL1010 adaptor. Load the CD into your computer and follow the setup instructions.

• If a CD is not available, the software is available for download from the Vector website (https://vector.com/ vi_downloadcenter_en.html).

Safety and warnings NOTE: Do not perform this procedure unless you have fully read and understand this document.

1.

Read this manual and other specified documentation in their entirety before servicing this equipment.

2.

Before performing this procedure, ensure that you have the proper skill and specialty training needed to perform this procedure as it applies to both the Nuvera® Fuel Cell System and all supplemental equipment used. If you feel that you are not qualified to perform this procedure, contact Nuvera Fuel Cells LLC.

3.

2.

Use caution when handling all parts in the fuel cell, as they may contain compressed hydrogen gas.

DANGER Hydrogen gas is flammable. Eliminate all ignition sources. Do not place an ignition source within 25 feet of this unit. DO NOT SMOKE WITHIN A 25 FOOT RADIUS OF THE FUEL CELL.

Load the software:

Locate the products and topics box (see Figure 33). a.

Scroll to the GL1000/GL1010 line and select it.

b.

Click the Show results button.

c.

The software file (Vector Logger Configurator 2.6 SP5 in this instance), will appear in the Description column below. See Figure 34.

d.

Scroll to the bottom of the Description column and select Download.

e.

Follow the prompt to download the software.

f.

Follow the installation instructions.

Parts and materials required Nuvera part number

Description

Qty.

N/A

CD

1

N/A

GL1000/ GL1010 software

1

Figure 33. Select software

Load the software NOTE: Software for the GL1010 Vector datalogger must be loaded on your computer in order to download the data-logger files.

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b.

Check the save raw logging data file box.

c.

You can also add a prefix to the file name by clicking on the destination file name bar, selecting add prefix and typing the BBR serial number in the prefix box.

Figure 34. Download software

Procedure 1.

Locate the USB cable provided with the datalogger. Use the USB cable to connect the data-logger to your PC.

2.

Start vector data-logger configuration tool.

Figure 36. Set up logger

NOTE: A dialogue box will prompt, asking to format SD card. DO NOT SELECT THIS. Formatting the SD card will erase all data recorded into the data-logger.

3.

d.

From the navigation pane on the left, select Logger Device. See Figure 35.

The same destination file bar will bring up Use custom file name. Click the Insert Macro bar and select {DATE_TIME}. This will name the file by the date and time with the prefix of the serial number that was added in the previous step. See Figure 37.

Figure 37. Insert Macro e.

Figure 35. Logger Device 4.

Set up logger for use. See Figure 36 for Step a. through Step c. below. a.

Select the Advanced Settings tab and confirm that Hexadecimal notation is selected. See Figure 38.

Set convert button to MS Excel file and the Extension button to txt.

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6.

Click the Convert button, to begin the conversion of all data stored into the datalogger. All converted files will be saved to the folder selected in the previous step, together with the native .clf file, and can be used by CANalyzer tool from Vector, in the instance converted files become lost corrupted, renamed, etc.). See Figure 41.

Figure 38. Hexadecimal notation f.

Select the Splitting Options tab and check the "Split text files..." box. See Figure 39.

Figure 41. Convert logged data

Figure 39. Splitting Options tab 5.

NOTE: Before deleting the logging data, confirm the data conversion process has finished and that all data was properly converted and saved.

Click the ellipsis button ( "..." ) to select the location folder for converted data files. See Figure 40.

7.

Click the Delete Logging Data button as shown in Figure 42. All data stored to the SD card will be erased.

Figure 40. Select ellipsis button

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Figure 42. Delete data from SD card

Figure 43. General Settings of conversion profile

Descriptions of adopted conversion profiles

Advanced Settings

General Settings • Files are converted to either ASCII format (.asc extension) or MS Excel File format (.txt extension).

• Source files are not automatically deleted after conversion process completion. Data can only be deleted by following the procedure in Step 7. This step is intended to ensure that data erased from the datalogger SD-card is deleted intentionally.

• Destination files are not overwritten.

• Raw logging data file (.clf extension) is saved in selected folder location.

• Destination file name is made so that files in the destination folder are sorted by chronological order, regardless if folder setting is meant to sort either by name or date. File names will have the following format: “yyyy_mm_dd_hh_mm_ss.asc” or “yyyy_mm_dd_hh_mm_ss.txt”).

40

• Hexadecimal notation is used for CAN IDs and Data into converted files.

• Conversion will NOT create a single file for all data logged, as file is typically too large.

Figure 44. Advanced Settings of conversion profile

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Splitting Options • Files are not split depending on their size.

Files are split depending on the hours of logging elapsed (namely, every 1 hour).

• The 1 hour splitting is made basing on the internal clock of the data-logger (“Real-time raster”); the result is that, apart from the first file of a logging session which starts at data-logger boot-up, the other files starts at every round hour – i.e. 08:00, 11:00…).

Figure 45. Splitting Options of conversion profiles

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Programming the VSM (Vehicle System Manager)

Safety and warnings NOTE: Do not perform this procedure unless you have fully read and understand this document.

1.

Read this manual and other specified documentation in their entirety before servicing this equipment.

2.

Before performing this procedure, ensure that you have the proper skill and specialty training needed to perform this procedure as it applies to both the Nuvera® Fuel Cell System and all supplemental equipment used. If you feel that you are not qualified to perform this procedure, contact Nuvera Fuel Cells LLC.

3.

Nuvera part number

Description

Qty.

1534009

HY orange 3 pin diagnostic cable

1

N/A

VSM programming tool

1

31004847

Vector family of CAN adapters

1

Setup Confirm the following, before proceeding to installation procedure:

Use caution when handling all parts in the fuel cell, as they may contain compressed hydrogen gas.

• Drivers for the communications adapter are installed and configured.

• Compatible and correct hex file(s) for programming are available.

DANGER

NOTE: Programming tool does not ensure hex file compatibility.

Hydrogen gas is flammable. Eliminate all ignition sources. Do not place an ignition source within 25 feet of this unit. DO NOT SMOKE WITHIN A 25 FOOT RADIUS OF THE FUEL CELL.

• Communications adapter is physically connected to CAN 1 on the Nuvera unit.

• Reliable power is available throughout the programming process.

Install

Parts and materials required Nuvera part number

Description

N/A

Windows 7 or 10

1

N/A

Permission to install applications to the C: drive

1

N/A

iFak is CAN BUS

1

Qty.

1.

Download the installation software "setupVsmProg" from Hypass.

2.

Run the installer.

• The installer will run quickly with no user input.

• The program will be installed at "C: \Program Files (x86)\VsmProg \SkunkProg.exe".

• The shortcut "VSM Prog tool" will be created in your Windows menu.

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Program 1.

Turn VSM power OFF.

2.

Launch VSM Prog tool. Select the correct micro controller you will be flashing in the top left corner (see Figure 46). In most cases you will be flashing micro controller 1. The selected controller will be highlighted in blue.

Figure 47. iFak driver If the Connect Vector button was selected, the following dialog will appear.

Figure 46. Select micro controller 3.

Ensure your communications adapter is connected and powered on.

4.

Select the appropriate button (Connect Vector or Connect iFak) for your communications adapter.

5.

If the Connect iFak button was selected, the following dialog will appear. Make selections as shown.

NOTE: VSM's with the Rev2 Bootloader use a Baud Rate of 500k.

6.

In the “Configure Vector CanCard Driver” window, select the hardware type you will be using. Once the appropriate driver is selected, click OK.

NOTE: VN1610 is selected in the image below.

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Figure 49. Configure 8.

Select the ellipses (...) button (see Figure 50).

Browse and select the hex file for Micro 1.

Figure 48. Configure Vector CanCard Driver 7.

The following screen will appear next (see, Figure 49). Select OK. This will return you to the main app window.

Figure 50. Ellipses button 9.

Ensure power to the VSM is still OFF (not in “programming mode”).

10. Click the Hold (CAN1) button.

11. Turn power to VSM ON (start “programming mode”). For fuel cell systems A2D1S01501R and after, this can be completed by pressing and holding the start button down for 4 seconds.

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12. Wait 5 seconds.

13. Click the Abort button.

14. Click the Program button.

15. A progress bar will indicate programming is in progress. This will take a few minutes. See Figure 51.

Figure 51. Progress bar 16. After green programming bar has reached 100%, select the E-stop button on the fuel cell system. If the fuel cell system does not have an E-stop, disconnect connector PJ002 (the wire harness that connects the fuel cell system to the truck).

17. Disconnect the adapter from the unit. Exit the application.

18. Programming is complete.

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Set up flags for VSM software 3.0.0

NOTE: This list does not include tools required for additional service procedures. Check the procedures below for necessary tools.

Safety and warnings NOTE: Do not perform this procedure unless you have fully read and understand this document.

1.

Read this manual and other specified documentation in their entirety before servicing this equipment.

2.

Before performing this procedure, ensure that you have the proper skill and specialty training needed to perform this procedure as it applies to both the Nuvera® Fuel Cell System and all supplemental equipment used. If you feel that you are not qualified to perform this procedure, contact Nuvera Fuel Cells LLC.

3.

Use caution when handling all parts in the fuel cell, as they may contain compressed hydrogen gas.

Procedure NOTE: More flags have been/will continue to be added as VSM Software is updated.

1.

From the FCS Service Tool Menu Bar: • Select Service > Start system into "Off" mode.

DANGER Hydrogen gas is flammable. Eliminate all ignition sources. Do not place an ignition source within 25 feet of this unit. DO NOT SMOKE WITHIN A 25 FOOT RADIUS OF THE FUEL CELL.

Tools required Figure 52. Start system into Off mode Nuvera part number

Description

Qty.

N/A

Laptop with Nuvera® FCS Service Tool installed

1

N/A

CAN-to-USB adapter (LeafLight v2.0 or similar)

1

N/A

IFAK cable

1

46

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Figure 54. Set flags

• DTC error code 108 will trigger, meaning VSM flags have not been set after flashing VSM. 2.

• Choose Block Version and the appropriate option for either Block 1 or Block 2. Select Apply.

From the FCS Service Tool Menu Bar: • Select Application > VSM Flags.

Figure 55. VSM Flags Table

Figure 53. Select VSM Flags

• Choose Coolant Sensor Manufacturer and the appropriate option for either GEMS or US Sensor. Select Apply.

• VSM Flags Table will be displayed. Values show as 255 unused when flags have not been set.

3.

Select Set Flags.

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Figure 56. VSM Flags Table_2 4.

Use the “X” button to close the VSM Flags Table. If using the engineering GUI version, Click on “Flush NVM” button. Give the system 20 seconds and stop the systems.

• Select Service > Stop System.

Figure 57. Stop system 5.

Start the unit normally and confirm DTC 108 has not triggered. The flags have now been setup.

6.

Verify the flag selection.

• Select Application > VSM Flags.

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Tools required

Removing and installing the engine sled

Scope To remove the engine sled in order to remove or service certain components.

Safety and warnings NOTE: Do not perform this procedure unless you have fully read and understand this document.

1.

2.

3.

Read this manual and other specified documentation in their entirety before servicing this equipment.

Nuvera part number

Description

Qty.

N/A

Socket set

1 set

N/A

Socket wrench

1

N/A

Hex head keys

1 set

NOTE: This list does not include tools required for additional service procedures. Check the procedures below for necessary tools.

Parts and materials required

Before performing this procedure, ensure that you have the proper skill and specialty training needed to perform this procedure as it applies to both the Nuvera® Fuel Cell System and all supplemental equipment used. If you feel that you are not qualified to perform this procedure, contact Nuvera Fuel Cells LLC.

Nuvera part number

Description

Qty.

N/A

D-clamps

2

N/A

Tow straps

2

Remove

Use caution when handling all parts in the fuel cell, as they may contain compressed hydrogen gas.

DANGER Hydrogen gas is flammable. Eliminate all ignition sources. Do not place an ignition source within 25 feet of this unit. DO NOT SMOKE WITHIN A 25 FOOT RADIUS OF THE FUEL CELL.

CAUTION 1.

All hydrogen fuel must be removed from the fuel cell system before attempting to remove the engine sled.

Use the Nuvera Fuel Cell System Service Tool 2. Confirm ultracapacitors are discharged. See to vent all hydrogen fuel from plumbing lines.

Discharging and recharging the See ultracapacitors.

Vent hydrogen from engine plumbing lines.

3. Close storage tank solenoid valves. See Opening and closing storage tank valves.

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4.

Remove the main cover from the fuel cell system. See Removing and installing the main cover.

5.

Remove the top access cover on the high pressure compartment. See Figure 58.

9.

Disconnect the dewatering hose. See Figure 60.

Figure 60. Disconnect/Connect dewatering line

Figure 58. High pressure compartment top access panel 6.

Remove the DC/DC 005 cover and disconnect the DC/DC connector.

7.

Use an 11/16" wrench to remove the Swagelok® nut on the hydrogen fuel line. See Figure 59.

10. Remove clamp. Apply Snoop® to the hose and pull the hose through to the other side of the bulkhead, making sure the grommet does not come free of the hole in the bulkhead.

11. Disconnect the display interface cable connector. See Figure 61.

Figure 61. Disconnect/Connect high pressure harness bulkhead connector NOTE: Always use Nuvera approved and ANSI rated lifting eyes, clamps, bolts, and chains.

Figure 59. Disconnect/Connect fuel line 8.

Use a 3/4" wrench to remove the bulkhead lock nut and disconnect the fuel line.

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12. Thread lifting eyes onto the main bracket.

Use 15mm socket to torque bolts to 30 N•m (22 lbf ft.). See Figure 62.

Figure 64. D-clamp with tow strap 15. Attach the tow straps to a lifting chain connected to an overhead crane. See Figure 65.

Figure 62. Lifting eyes 13. Feed a tow strap through each lifting eye and attach the tow strap to a lifting chain connected to an overhead crane. See Figure 63.

Figure 65. Attach tow straps to lifting chain 16. Remove the two bolts connecting the sled to the bottom of the fuel cell frame. Remove the bolt holding the sled to the side of the frame.

Figure 63. Feeding tow strap through lifting eyes 14. Install two D-clamps, with tow straps, onto the brackets attached to the other sidewall of the sled. See Figure 64.

51

17. Use the overhead crane to SLOWLY lift the engine sled up. Pull the engine sled toward you until the hydrogen fuel line feed is free from the hole in the bulkhead. When the fitting is free, pull the sled up and out of the fuel cell system. See Figure 66.

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Figure 66. Remove/Install sled from fuel cell 18. Move the engine sled to the work surface.

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Install

12. Connect the DC/DC 005 connector and install the cover.

NOTE: Always use Nuvera approved and ANSI rated lifting eyes, clamps, bolts, and chains.

13. Install the top access cover on the high pressure compartment. Insert screws and tighten to 34.8 N•m (26 lbf ft.). See Figure 58.

1.

Thread lifting eyes onto the main bracket. See Figure 62.

2.

Feed a tow strap through each lifting eye and attach the tow strap to a lifting chain connected to an overhead crane. See Figure 63.

3.

Install two D-clamps, with tow straps, onto the brackets attached to the other sidewall of the sled. See Figure 64.

4.

Attach the tow straps to a lifting chain connected to an overhead crane. See Figure 65.

5.

Use the overhead crane to SLOWLY lift the engine sled up from work surface and into the fuel cell system, taking care to feed the hydrogen fuel line through the hole in the bulkhead. See Figure 66.

15. Recharge the ultracapacitors. See Discharging and recharging the ultracapacitors.

Lower the engine sled down entirely. Tighten the bolts to 52 N•m (38 lbf ft.).

8.

Feed high pressure harness bulkhead connector, dewatering hose, and fuel line through to the high pressure compartment.

9.

Connect the high pressure harness bulkhead connector. See Figure 61.

PowerEdge Replacement Stack Commissioning and Dormant BBR Startup Procedure (Class I and II)

Process for replacement stack commissioning and dormant BBR startup.

Safety and warnings NOTE: Do not perform this procedure unless you have fully read and understand this document.

Leave a small amount of tension on the tow straps and lifting chain, and align the bolt holes on the sled with the holes on the fuel cell system. Apply Loctite to the bolts and insert.

7.

16. Perform anode loop leak check. See Leak check anode loop.

Scope

NOTE: Leave a small amount of tension on the tow straps and lifting chain, to aid in lining up the bolt holes.

6.

14. Install the main cover to the fuel cell system.

See Removing and installing the main cover.

1.

Read this manual and other specified documentation in their entirety before servicing this equipment.

2.

Before performing this procedure, ensure that you have the proper skill and specialty training needed to perform this procedure as it applies to both the Nuvera® Fuel Cell System and all supplemental equipment used. If you feel that you are not qualified to perform this procedure, contact Nuvera Fuel Cells LLC.

10. Connect the dewatering hose. See Figure 60.

11. Connect the fuel line. See Figure 59.

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3.

• Discharging and recharging the ultracapacitors • Draining and filling coolant • Replacing the air filter

Use caution when handling all parts in the fuel cell, as they may contain compressed hydrogen gas.

DANGER

2.

Hydrogen gas is flammable. Eliminate all ignition sources. Do not place an ignition source within 25 feet of this unit. DO NOT SMOKE WITHIN A 25 FOOT RADIUS OF THE FUEL CELL.

Launch the Service Tool GUI, ensure it is set to Log Data and Temporarily Disable EFD. Then start the BBR normally and allow a minute for the startup sequence to complete before applying any load.

Tools required Nuvera part number

Description

Qty.

31004773

Load Bank

1

N/A

Laptop with Nuvera® FCS Service Tool installed

1

NOTE: This list does not include tools required for additional service procedures. Check the procedures below for necessary tools.

Parts and materials required Nuvera part number

Description

Qty.

31005527

95 Cell Stack FRU

1 Figure 67. Service tool GUI

Replacing or restarting a stack 1.

3.

Follow this procedure after replacing a stack, or when starting up any stack (or BBR) which has not been operated for at least 90 days.

NOTE: Before continuing make sure ultracapacitors have been charged (to 56V for Class 1 and 41V for Class 2), coolant has been filled/topped off, and a new air filter has been installed following the appropriate procedures: 54

Ensure the load bank’s current setting is minimized, then engage the load. Gradually increase load current until the stack current reaches 40A (load current should be approximately 50A for Class 1 and 60A for Class 2, but will vary a bit based on stack’s average cell voltage). Hold this condition for 2 minutes to ensure stable operation before increasing current any further. www.nuvera.com

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4.

Slowly ramp up the load over a period of 30 seconds to achieve 125A on the stack (load current should be approximately 160A for Class 1 and 210A for Class 2, but will vary a bit based on stack’s average cell voltage) – closely monitor the cell voltages using the Service Tool, looking for low cell performance signatures.

NOTE: Use care when ramping load bank setpoint, as system will want to “step” towards 155A by default. This can be mitigated by increasing load very slowly once at 90A. Some overshoot may be inevitable, but this is fine as long as the stack does not exceed 155A.

C.

D. If no low cells are identified hold this condition for 15 minutes after coolant inlet temperature has reached setpoint, then continue to Step 6.

NOTE: Load bank setpoint may need to be adjusted to maintain stack current at 125A due to increase in thermal management parasitics.

5.

Evaluate stack water balance A. Induced flooding conditions (ReHydration):

A. If a low individual cell (>60mV below average, or <600mV absolute) is identified during the ramp, stop ramping up the current and allow the system to stabilize at whatever current the weakest cell can maintain, constantly monitoring the cell.

Continue to Step 5.

B.

• If the signature remains at the end of the 15 minute hold, proceed to Step 5.

If a low individual cell emerges during the hold period at 125A, gradually decrease the load current until the cell rebounds and allow the system to stabilize at whatever current the problem cell can maintain. Ensure that the stack current remains at least >40A. Continue to Step 5.

If several consecutive low cells are identified (eg. “smiley face” signature), stop this procedure and verify the coolant level, making sure the system is completely filled. Then restart this procedure.

1.

• If minimum cell voltage increases by at least 5mV, maintain this condition until the until the upward trend stops and flattens out.

Then return to nominal coolant inlet temperature setpoint and continue to Step 6.

2.

B.

55

If minimum cell voltage decreases by 5mV or more, return to nominal coolant setpoint and continue to Step B.

Induced drying conditions (DeHydration): 1.

• If this behavior persists even after confirming coolant level, continue holding at 125A for 15 minutes after coolant inlet temperature has reached setpoint, as long as the minimum cell voltage remains >600mV.

Reduce coolant inlet temperature setpoint by -5°C, wait for the actual temperature to stabilize at this new setpoint, and closely monitor the minimum and average cell voltages over the next 2 minutes.

Increase coolant inlet temperature setpoint by +5°C, wait for the actual temperature to stabilize at this new setpoint, and closely monitor minimum and average cell voltages over the next 2 minutes. www.nuvera.com

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• If minimum cell voltage increases by at least 5mV, maintain this condition until the until the upward trend stops and flattens out.

Then return to nominal coolant setpoint and continue to Step 6.

5.

Increase load bank setting to achieve 195A stack current. This load current should be approximately 220A for Class 1 or 280A for Class 2, but will vary a bit based on stack health.

Remain in this condition for 3 minutes.

6.

If the unit’s coolant inlet temperature is > 1°C higher than setpoint, reduce the load current to 120A until temperature is back under control.

Otherwise, proceed to next step.

7.

Increase load bank setting to achieve 235A stack current. This load current should be approximately 280A for Class 1 or 340A for Class 2, but will vary a bit based on stack health.

Remain in this condition for 30 seconds.

8.

Reduce the load current to 120A until temperature is back under control.

Increase load bank setting to achieve 155A stack current. This load current should be approximately 180A for Class 1 or 250A for Class 2, but will vary a bit based on stack health.

Remain in this condition for 3 minutes.

9.

Increase load bank setting to achieve 275A stack current, max power. This typically requires load bank current to be maxed out, ~450-500A. Remain in this condition for 20 seconds.

If the unit’s coolant inlet temperature is >1°C higher than setpoint, reduce the load current to 120A until temperature is back under control.

Otherwise, proceed to next step.

11. Press Stop button to initiate system shutdown.

2.

6.

If minimum cell voltage decreases by 5mV or more (and Step A. also produced a similar voltage drop), contact HY Field Service and/or Nuvera Product Support.

Initiate standard performance check as per below: 1.

Launch the Service Tool GUI, ensure it is set to Log Data and Temporarily Disable EFD.

2.

Start unit normally, wait for it to enter Run state, then apply 120A load current until unit warms up and coolant inlet temperature reaches its setpoint.

3.

4.

10. Reduce the load current to 120A until temperature is back under control.

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Nuvera® Fuel Cell System C95A-33 Service Manual

Service procedures

Opening and closing storage tank valves

Scope

Open and close storage tank solenoid valves 1.

To open and close the solenoid valve on the hydrogen storage tanks.

Locate the high pressure compartment access panel. See Figure 68.

Safety and warnings NOTE: Do not perform this procedure unless you have fully read and understand this document.

1.

Read this manual and other specified documentation in their entirety before servicing this equipment.

2.

Before performing this procedure, ensure that you have the proper skill and specialty training needed to perform this procedure as it applies to both the Nuvera® Fuel Cell System and all supplemental equipment used. If you feel that you are not qualified to perform this procedure, contact Nuvera Fuel Cells LLC.

3.

Use caution when handling all parts in the fuel cell, as they may contain compressed hydrogen gas.

Figure 68. High pressure compartment access panel

DANGER Hydrogen gas is flammable. Eliminate all ignition sources. Do not place an ignition source within 25 feet of this unit. DO NOT SMOKE WITHIN A 25 FOOT RADIUS OF THE FUEL CELL.

Tools required Nuvera part number

Description

Qty.

N/A

3/16" T-handle hex head key

1

1.

CAPSCREW

3.

HIGH PRESSURE COMPARTMENT

2.

ACCESS PANEL

2.

Use the 4 mm hex head key to remove the six capscrews securing the access panel to the fuel cell. Remove access panel.

3.

Locate the two storage tank solenoid valves.

See Figure 69.

NOTE: This list does not include tools required for additional service procedures. Check the procedures below for necessary tools.

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Service procedures

Figure 69. Storage tank shutoff valve 1.

STORAGE TANK SOLENOID VALVE

2.

MANUAL LOCKDOWN

4.

Locate the manual lockdown in the center of the storage tank solenoid valve.

5.

Use a 3/16 hex head wrench to turn lockdown screw clockwise to close or counterclockwise to open.

NOTICE Make sure the hex head wrench is fully inserted and square to the hole before starting to turn. Use straight-edged wrench instead of ball head wrench to avoid stripping the brass screw. Do not over-torque. This may damage the valve.

6.

Install the high pressure compartment access panel. See Figure 68.

7.

Insert the capscrews to secure access panel to fuel cell. See Figure 68.

8.

Use 4 mm hex head key to tighten capscrews.

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Service procedures

Draining and filling coolant

Scope To fill the fuel cell system with coolant.

Nuvera part number

Description

Qty.

N/A

Laptop with Nuvera® FCS Service Tool

1

N/A

CAN-to-USB adapter (LeafLight v2.0 or similar)

1

N/A

HY standard diagnostic cable (3 pin Deutsch to DB9)

1

31001222

Coolant

AR

Safety and warnings NOTE: Do not perform this procedure unless you have fully read and understand this document.

1.

Read this manual and other specified documentation in their entirety before servicing this equipment.

2.

Before performing this procedure, ensure that you have the proper skill and specialty training needed to perform this procedure as it applies to both the Nuvera® Fuel Cell System and all supplemental equipment used. If you feel that you are not qualified to perform this procedure, contact Nuvera Fuel Cells LLC.

3.

NOTE: This list does not include tools required for additional service procedures. Check the procedures below for necessary tools.

Use caution when handling all parts in the fuel cell, as they may contain compressed hydrogen gas.

Drain coolant 1.

Confirm ultracapacitors are discharged. See Discharging and recharging the ultracapacitors.

2.

Remove the main cover. See Removing and installing the main cover.

3.

Locate the heater (HTR303) on the condensate tank. See Figure 70 or Figure 71.

DANGER Hydrogen gas is flammable. Eliminate all ignition sources. Do not place an ignition source within 25 feet of this unit. DO NOT SMOKE WITHIN A 25 FOOT RADIUS OF THE FUEL CELL.

Tools required Nuvera part number

Description

Qty.

N/A

Ratchet

1

N/A

22 mm (7/8 in.)

Oxygen Sensor thin wall socket

1

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Nuvera® Fuel Cell System C95A-33 Service Manual

Service procedures

CONDENSATE TANK

2.

Hold the hose nozzle of the wet/dry vacuum close enough to the coolant heater to suction up any coolant drips.

7.

Slowly unscrew the coolant heater with the 22 mm socket. Do not remove coolant heater immediately, wait for the flow of coolant to slow, then remove gradually.

8.

With heater removed, place the vacuum hose over the heater opening. Remove radiator cap, and suction out any remaining coolant.

9.

Once the coolant is drained reinsert coolant heater. Reapply Teflon tape to the coolant heater threads.

10. Tighten the coolant heater until snug.

Figure 70. Heater (HTR303), fuel cell systems up to and including S/N A2D1S01500R 1.

6.

NOTE: No torque value is required since heater is NPT threaded.

HEATER

11. Reconnect the wire leading to the coolant heater, HTR303.

Refill coolant NOTE: If the coolant is being filled following a fuel cell stack replacement, then the coolant loop must be pressure tested before adding any coolant. See Leak check coolant loop. A leak check of the anode loop must also be performed before returning the fuel cell system back into operation. See Leak check anode loop.

Figure 71. Heater (HTR303), fuel cell systems S/N A2D1S01501R and after 1.

CONDENSATE TANK

2.

4.

Disconnect the wire leading to the coolant heater, HTR303.

5.

Place an empty waste bin under the coolant heater.

1.

See Set up for external supply of nominal bus voltage and follow all steps.

2.

From the FCS Service Tool Menu Bar: • Select Service > Coolant Fill.

HEATER

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Service procedures

Figure 72. Coolant Fill 3.

A new window will appear, detailing the next step. Follow the prompts from the service tool.

4.

Pack the top of the radiator with absorbent towels, and remove the radiator vent port screw slowly, releasing any built up pressure from the radiator.

5.

See Revert to normal ultracaps connection and follow all steps.

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Service procedures

Tools required

Draining and filling coolant (systems with vented stack)

Scope To fill the fuel cell system with coolant.

NOTE: This procedure only applies to class I and class II systems that include a fuel cell stack equipped with coolant bleed ports.

This procedure should be used in all instances of adding coolant to class I and class II systems: • Initial coolant fills • Coolant changes and top-offs (scheduled and unscheduled)

Safety and warnings

Nuvera part number

Description

Qty.

N/A

Variable voltage power supply

1

N/A

Laptop with Nuvera® FCS Service Tool

1

N/A

22 mm (7/8 in.) oxygen sensor socket

1

N/A

Ratchet socket drive (drive size matches that of 22 mm socket)

1

N/A

4 to 6 Gallon capacity wet/dry vacuum cleaner

1

N/A

2 to 3 gallon bucket

1

N/A

4 mm hex head key

1

N/A

M8 X 12 button head cap screw

1

NOTE: Do not perform this procedure unless you have fully read and understand this document.

1.

Read this manual and other specified documentation in their entirety before servicing this equipment.

2.

Before performing this procedure, ensure that you have the proper skill and specialty training needed to perform this procedure as it applies to both the Nuvera® Fuel Cell System and all supplemental equipment used. If you feel that you are not qualified to perform this procedure, contact Nuvera Fuel Cells LLC.

3.

Use caution when handling all parts in the fuel cell, as they may contain compressed hydrogen gas.

NOTE: This list does not include tools required for additional service procedures. Check the procedures below for necessary tools.

DANGER Hydrogen gas is flammable. Eliminate all ignition sources. Do not place an ignition source within 25 feet of this unit. DO NOT SMOKE WITHIN A 25 FOOT RADIUS OF THE FUEL CELL.

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Service procedures

Tools required Nuvera part number

Description

Qty.

31001222

Fuel cell antifreeze/ coolant

1

31004591

Fuel cell system class I and II coolant fill kit

1 Figure 73. Coolant recovery tank

Procedure 1.

Confirm ultracapacitors are discharged. See Discharging and recharging the ultracapacitors.

2.

Remove the main cover. See Removing and installing the main cover.

3.

Connect the variable voltage power supply to the ultracapacitor module buss bars. See Set up for external supply of nominal bus voltage.

4.

Confirm engine is in "OFF" state.

5.

Use the 4 mm hex head key to remove the three mounting screws from the top of the coolant overflow reservoir. See Figure 73.

6.

Remove the cap from the coolant recovery tank. See Figure 73.

7.

Lift the recovery tank off and away from the fuel cell stack. Turn tank upside down to drain all coolant out of the tank through the cap opening. Catch all the fluid from the tank into the bucket. See Figure 74.

1.

MOUNTING SCREWS

3.

COOLANT RECOVERY TANK

2.

RECOVERY TANK CAP

4.

FUEL CELL STACK

Figure 74. Drain coolant

63

1.

COOLANT TANK (UPSIDE DOWN)

3.

LOWER COOLANT RECOVERY TUBE

2.

CAP OPENING

4.

HOSE CLAMP

8.

Loosen the hose clamp that secures the lower coolant recovery tube to the coolant recovery tank. Detach the tube from the tank and set the tank aside. See Figure 74.

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Nuvera® Fuel Cell System C95A-33 Service Manual

Service procedures

9.

Plug the open end of the lower coolant recovery tube with the button head cap screw. Lightly tighten the hose clamp around the tube and the screw. See Figure 75.

Figure 76. Heater (HTR303), fuel cell systems up to and including S/N A2D1S01500R 1.

Figure 75. Plug the hose

CONDENSATE TANK

2.

HEATER

NOTE: If this is the initial fill, follow Step 10. through Step 16. If this is not the system’s initial coolant fill, proceed to 10. Disconnect the coolant heater power connector (HTR303). See Figure 76 or Figure 77.

Figure 77. Heater (HTR303), fuel cell systems S/N A2D1S01501R and after 1.

CONDENSATE TANK

2.

HEATER

11. Hold the hose nozzle of the wet/dry vacuum cleaner close enough to the coolant heater to suction up any coolant drips.

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12. Turn on the wet/dry vacuum cleaner and slowly unscrew the coolant heater with the 22 mm socket. Do not remove the coolant heater immediately. Wait for the flow of coolant to slow, then remove gradually.

18. Confirm the heater is installed and tightened properly for system operation.

19. Locate the fuel cell system coolant fill kit.

20. Locate the modified funnel adapter, from the kit and install into the radiator filler neck well.

See Figure 79.

13. With the heater removed, place the hose nozzle of the wet/dry vacuum cleaner over the heater opening in the condensate tank.

Remove the radiator cap and continue to suction out any remaining coolant through the heater opening.

14. Once all coolant has been drained from the coolant loop, re-apply Teflon® tape to the coolant heater threads and reinstall the coolant heater into the condensate tank.

15. Tighten the coolant heater until snug (no torque value is required since the heater is NPT threaded).

16. Reconnect the coolant heater power connector.

Figure 79. Funnel adapter

17. Remove the radiator cap and set it aside. See Figure 78.

1.

FUNNEL ADAPTER

2.

ADAPTER GASKET

3.

RADIATOR FILLER NECK WELL

21. Locate the medium radiator cap in the funnel kit, and install it over the funnel adapter and onto the radiator filler neck. See Figure 80.

Figure 78. Radiator cap 1.

RADIATOR CAP

2.

RADIATOR VENT PLUG

Figure 80. Medium radiator cap 65

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Service procedures

22. Locate the 5 inch funnel extension in the funnel kit, and install into the funnel adapter.

See Figure 81.

24. Remove the stack bleed port plug that is over the coolant return side of the stack and closest to the radiator. See Figure 83.

Figure 83. Bleed port plug

Figure 81. Funnel extension

25. Locate the coolant suction tube assembly in the kit and thread it into the open stack bleed port. Hand tighten until the O-ring is slightly compressed against the stack end plate. See Figure 84.

23. Locate the funnel in the funnel kit, and install it into the funnel extension. See Figure 82.

Figure 84. Coolant suction tube

Figure 82. Funnel NOTE: Do not disturb the four stack compression bolts, when removing the bleed port plug.

66

1.

COOLANT SUCTION TUBE

2.

STACK END PLATE

3.

O-RING

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Nuvera® Fuel Cell System C95A-33 Service Manual

Service procedures

26. Locate the coolant hand pump in the kit.

32. Pour coolant into the system through the funnel until the funnel is approximately ¾ full. See Figure 86.

27. Install the open end of the coolant suction tube assembly into the suction port of the coolant hand pump. Follow the pump manufacturer’s instructions for installing/ locking the tube. See Figure 85.

28. Locate the coolant discharge tube from the kit. Install one end of the tube into the discharge port of the coolant hand pump.

Place the other end of the discharge tube into the funnel. Follow the pump manufacturer’s instructions for installing/locking the tube.

Figure 85.

• The coolant will first fill the radiator and some of the other system volume before the ¾ volume of the funnel can be achieved.

• The funnel creates a temporary coolant high point for bleeding air from the system.

Figure 86. Coolant fill 33. While keeping the free end of the discharge tube in the funnel, pump the hand pump a few times until the coolant in the funnel drops either partially or fully into the radiator. Keep the free end of the discharge tube in the funnel so that any coolant drawn from the stack is recirculated back into the coolant loop.

Figure 85. coolant suction and discharge tubes 1.

COOLANT HAND PUMP

4.

PUMP DISCHARGE PORT

2.

PUMP SUCTION PORT

5.

COOLANT DISCHARGE TUBE

3.

COOLANT SUCTION TUBE

6.

FUNNEL

29. Switch on the power supply that was installed in Step 3.

NOTE: This hand pump is single-action. All fluid motion (suction/discharge) takes place on the inward stroke of the piston only.

30. Use the laptop/Nuvera FCS service tool, to set the engine to “OFF” state. See Start into off mode.

31. From the Nuvera FCS service tool, set the three-way valve position to 50%.

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Service procedures

38. Slowly pump the hand pump until the coolant level in the funnel recedes to just below the bottom surface of the radiator filler neck well. This can be monitored through the funnel and funnel extension.

NOTE: Stop pumping once that fluid level is reached. The displaced funnel fluid will exit the discharge tube into the bucket.

39. Uninstall the coolant suction tube assembly from the stack bleed port. Leave the suction and discharge tubes assembled to the hand pump for cleaning.

40. Re-install the stack bleed port plug that was removed previously. See Figure 83.

Figure 87. Coolant pump 34. Repeat Step 32. and Step 33. until the coolant in the funnel no longer drops into the radiator and remains at a steady volume of about ¾ full.

35. While keeping the free end of the discharge tube submerged in the funnel coolant, pump the hand pump slowly and continuously.

System coolant and air will be drawn from the stack, through the pump and into the funnel where air bubbles will escape to atmosphere and the coolant will recirculate back into the coolant loop. As coolant displaces air, add coolant to the funnel as required to keep ¾ full.

41. Reattach the coolant recovery tank to the fuel cell stack, as removed in Step 5. through Step 8.

42. Loosen the hose clamp and remove the screw that was installed into the lower coolant recovery tube in Step 9. Store the screw for future use.

43. Re-attach the lower coolant recovery tube to the coolant recovery tank and secure with the hose clamp.

44. Re-attach the cap to the coolant recovery tank. See Figure 73.

45. Remove the funnel, funnel extension, radiator cap and funnel adapter from the radiator filler neck.

36. As pumping continues, once no air bubbles are visible in the coolant suction tube, the coolant discharge tube or the funnel coolant, the cooling system is full and all air has been bled.

37. Stop pumping and remove the free end of the coolant discharge tube from inside the funnel and insert it into the bucket.

68

46. The coolant level should be just below the bottom surface of the radiator filler neck well. If it is not, top it off to that level now.

See Figure 88.

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Nuvera® Fuel Cell System C95A-33 Service Manual

Service procedures

2.

Flush the hand pump and tubes by submerging the free end of the suction tube in water, inserting the free end of the discharge tube into the bucket, and pumping the handle a few times. To dry, remove the suction tube from the water and pump the handle a few more times so that only air is being drawn and discharged by the pump.

Store for future use.

3.

Discard all coolant in the wet/dry vacuum cleaner reservoir and in the bucket.

Figure 88. Coolant fill neck 47. Reinstall the system radiator cap that was removed in Step 17.

48. Remove the cap to the coolant recovery tank and pour coolant into the tank until the level reaches the “FULL” line. Reinstall the tank cap and secure hand tight. See Figure 73.

49. If the coolant is being filled following a fuel cell stack replacement: • The coolant loop must be pressure tested before adding any coolant. See Leak check coolant loop.

• A leak check of the anode loop must be performed before returning to operation.

See Leak check anode loop.

50. Power off and disconnect the power supply that was installed in Set up for external supply of nominal bus voltage.

51. Re-install the main cover. See Removing and installing the main cover.

Cleaning 1.

Rinse all filling kit parts (funnel, funnel extension, funnel adapter and radiator cap) with water. Store for future use.

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Nuvera® Fuel Cell System C95A-33 Service Manual

Service procedures

Replacing the air filter

2.

Locate the air inlet assembly. See Figure 89.

Scope To remove the air filter and replace with new.

Safety and warnings NOTE: Do not perform this procedure unless you have fully read and understand this document.

1.

Read this manual and other specified documentation in their entirety before servicing this equipment.

2.

Before performing this procedure, ensure that you have the proper skill and specialty training needed to perform this procedure as it applies to both the Nuvera® Fuel Cell System and all supplemental equipment used. If you feel that you are not qualified to perform this procedure, contact Nuvera Fuel Cells LLC.

3.

Figure 89. Air inlet assembly

Use caution when handling all parts in the fuel cell, as they may contain compressed hydrogen gas.

DANGER

1.

WINGHEAD SCREW

2.

AIR INLET COVER

3.

AIR INLET ASSEMBLY

3.

Turn the two wing-head screws counterclockwise to loosen.

4.

Remove wing-head screws and air inlet cover.

NOTE: When removing the air filter, take care to not lose the O-ring that is seated between the filter and the adapter.

Hydrogen gas is flammable. Eliminate all ignition sources. Do not place an ignition source within 25 feet of this unit. DO NOT SMOKE WITHIN A 25 FOOT RADIUS OF THE FUEL CELL.

5.

Locate air filter inside air inlet assembly. See Figure 90.

Parts and materials required Nuvera part number

Description

Qty.

31001375

Air filter

1

Remove 1.

Remove the air filter service cover. See Removing and installing the main cover for procedure.

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Nuvera® Fuel Cell System C95A-33 Service Manual

Service procedures

Install

CAUTION The filter must be properly installed to ensure adequate engine protection. An improperly installed filter may allow dirt and dust to enter and damage the engine.

Figure 90. Air filter 6.

Lift air filter up to remove. Inspect the O-ring.

See Figure 91.

1.

Install new air filter inside air inlet assembly.

See Figure 90. Replace O-ring.

2.

Install air inlet cover and wing-head screws.

Turn the screws clockwise. Tighten to fingertight.

3.

Re-install the air filter service cover. See Removing and installing the main cover for procedure.

Figure 91. Air filter O-ring

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Nuvera® Fuel Cell System C95A-33 Service Manual

Service procedures

Replacing the coolant filter (fuel cell systems up to and including S/N A2D1S01500R)

NOTE: This list does not include tools required for additional service procedures. Check the procedures below for necessary tools.

Scope

Parts and materials required

To remove the coolant filter and replace with new.

Safety and warnings NOTE: Do not perform this procedure unless you have fully read and understand this document.

1.

Read this manual and other specified documentation in their entirety before servicing this equipment.

2.

Before performing this procedure, ensure that you have the proper skill and specialty training needed to perform this procedure as it applies to both the Nuvera® Fuel Cell System and all supplemental equipment used. If you feel that you are not qualified to perform this procedure, contact Nuvera Fuel Cells LLC.

3.

Nuvera part number

Description

Qty.

N/A

Coolant filter

1

Remove 1.

Confirm ultracapacitors are discharged. See Discharging and recharging the ultracapacitors.

2.

Remove the main cover. See Removing and installing the main cover for procedure.

3.

Locate the coolant filter bracket under the main bracket. See Figure 92.

Use caution when handling all parts in the fuel cell, as they may contain compressed hydrogen gas.

DANGER Hydrogen gas is flammable. Eliminate all ignition sources. Do not place an ignition source within 25 feet of this unit. DO NOT SMOKE WITHIN A 25 FOOT RADIUS OF THE FUEL CELL.

Figure 92. Coolant filter hardware

Tools required Nuvera part number

Description

Qty.

N/A

4 mm hex head key

1

72

1.

CAPSCREW

3.

STAR WASHER

2.

WASHER

4.

COOLANT FILTER BRACKET

4.

Use the 4 mm hex head key and loosen the two screws holding the coolant filter bracket to the main bracket. See Figure 92.

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Nuvera® Fuel Cell System C95A-33 Service Manual

Service procedures

5.

Lift the coolant filter and bracket up and out of the fuel cell system, to access hoses.

6.

Disconnect the hoses from the fittings. (2, Figure 93).

6.

Recharge ultracapacitors. See Discharging and recharging the ultracapacitors.

Figure 93. Remove coolant filter 1.

COOLANT FILTER BRACKET

3.

MANIFOLD

2.

FITTINGS

4.

FILTER

7.

Remove the bracket from the filter (1, Figure 93). Discard filter.

Install 1.

Locate the new filter and attach the bracket.

Tighten screws. See Figure 93.

2.

Install the filter and filter bracket into the fuel cell system. Allign the filter bracket with the main bracket. See Figure 93.

3.

Insert the washers and capscrews to attach filter bracket to main bracket.

4.

If any coolant was lost, add coolant. See Draining and filling coolant or Draining and filling coolant (systems with vented stack).

5.

Reinstall cover. See Removing and installing the main cover.

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Nuvera® Fuel Cell System C95A-33 Service Manual

Service procedures

Replacing the coolant filter (fuel cell systems S/N A2D1S01501R and after)

NOTE: This list does not include tools required for additional service procedures. Check the procedures below for necessary tools.

Scope

Parts and materials required

To remove the coolant filter and replace with new.

Safety and warnings

Nuvera part number

Description

Qty.

N/A

Coolant filter

1

NOTE: Do not perform this procedure unless you have fully read and understand this document.

Remove

1.

Read this manual and other specified documentation in their entirety before servicing this equipment.

1.

Confirm ultracapacitors are discharged. See Discharging and recharging the ultracapacitors.

2.

Before performing this procedure, ensure that you have the proper skill and specialty training needed to perform this procedure as it applies to both the Nuvera® Fuel Cell System and all supplemental equipment used. If you feel that you are not qualified to perform this procedure, contact Nuvera Fuel Cells LLC.

2.

Remove the main cover. See Removing and installing the main cover for procedure.

3.

Locate the coolant filter bracket attached to the main bracket. See Figure 94.

3.

Use caution when handling all parts in the fuel cell, as they may contain compressed hydrogen gas.

DANGER Hydrogen gas is flammable. Eliminate all ignition sources. Do not place an ignition source within 25 feet of this unit. DO NOT SMOKE WITHIN A 25 FOOT RADIUS OF THE FUEL CELL.

Tools required Nuvera part number

Description

Qty.

N/A

4 mm hex head key

1

Figure 94. Coolant filter hardware

74

1.

CAPSCREW

3.

STAR WASHER

2.

WASHER

4.

COOLANT FILTER BRACKET

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Nuvera® Fuel Cell System C95A-33 Service Manual

Service procedures

4.

Use the 4 mm hex head key and loosen the two screws holding the coolant filter bracket to the main bracket. See Figure 94.

5.

6.

4.

Lift the coolant filter up and out of the fuel cell system, to access hoses.

If any coolant was lost, add coolant. See Draining and filling coolant or Draining and filling coolant (systems with vented stack).

5.

Disconnect the hoses from the fittings (2, Figure 95).

Reinstall cover. See Removing and installing the main cover.

6.

Recharge ultracapacitors. See Discharging and recharging the ultracapacitors.

Figure 95. Remove coolant filter 1.

COOLANT FILTER BRACKET

3.

MANIFOLD

2.

FITTINGS

4.

FILTER HOUSING

7.

Remove the bracket from the filter (1, Figure 95). Discard filter.

Install 1.

Locate the new filter and attach the bracket.

Tighten the screws. See Figure 95.

2.

Install the filter and filter bracket into the fuel cell system. Allign the filter bracket with the main bracket. See Figure 94.

3.

Insert the washers and capscrews to attach the filter bracket to the main bracket.

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Service procedures

Replacing the wicking filter

Remove

Scope

1.

To remove the radiator wicking filter and replace with new.

Use the 4 mm hex key to remove the eight flat head bolts from the radiator cover. See Figure 96.

Safety and warnings NOTE: Do not perform this procedure unless you have fully read and understand this document.

1.

Read this manual and other specified documentation in their entirety before servicing this equipment.

2.

Before performing this procedure, ensure that you have the proper skill and specialty training needed to perform this procedure as it applies to both the Nuvera® Fuel Cell System and all supplemental equipment used. If you feel that you are not qualified to perform this procedure, contact Nuvera Fuel Cells LLC.

3.

Figure 96. Radiator cover 1.

SCREW

2.

RADIATOR COVER

Use caution when handling all parts in the fuel cell, as they may contain compressed hydrogen gas.

DANGER Hydrogen gas is flammable. Eliminate all ignition sources. Do not place an ignition source within 25 feet of this unit. DO NOT SMOKE WITHIN A 25 FOOT RADIUS OF THE FUEL CELL.

Parts and materials required Nuvera part number

Description

Qty.

N/A

Wicking filter

1

Figure 97. Wicking filter

76

1.

WICKING FILTER

3.

BOLT

2.

FILTER FRAME

2.

Locate the wicking filter next to the radiator.

See Figure 97.

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Nuvera® Fuel Cell System C95A-33 Service Manual

Service procedures

3.

4.

Use the 10 mm wrench to remove the two bolts attaching the wicking filter frame to the radiator. See Figure 97.

Remove the wicking filter from the radiator.

See Figure 98.

3.

Fold the filter up so it is in contact with the radiator. Install the filter frame.

4.

Insert the two bolts through the holes in the filter frame to attach the frame to the radiator. Use the 10 mm wrench to tighten the bolts. See Figure 97.

5.

Re-install the radiator cover using the eight flathead bolts. Use the 4 mm hex key to tighten. See Figure 96.

Figure 98. Radiator with wicking filter removed

Install 1.

Locate the new wicking filter.

2.

Insert the long edge of the wicking filter into the slot under the radiator. See Figure 99.

Tuck the filter 12 to 15 mm into the slot.

Figure 99. Install new wicking filter

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Nuvera® Fuel Cell System C95A-33 Service Manual

Service procedures

Removing and installing the radiator

NOTE: This list does not include tools required for additional service procedures. Check the procedures below for necessary tools.

Scope

Remove

To remove the radiator for cleaning or replacement and install.

CAUTION

Safety and warnings

All hydrogen fuel must be removed from the fuel cell system before attempting to remove the engine sled.

NOTE: Do not perform this procedure unless you have fully read and understand this document.

1.

Read this manual and other specified documentation in their entirety before servicing this equipment.

2.

Before performing this procedure, ensure that you have the proper skill and specialty training needed to perform this procedure as it applies to both the Nuvera® Fuel Cell System and all supplemental equipment used. If you feel that you are not qualified to perform this procedure, contact Nuvera Fuel Cells LLC.

3.

1.

Confirm all hydrogen fuel has been vented and remove the engine sled to gain access to the radiator. See Removing and installing the engine sled.

2.

Drain coolant from radiator. See Draining and filling coolant.

3.

Disconnect fan connectors. See Figure 100.

Use caution when handling all parts in the fuel cell, as they may contain compressed hydrogen gas.

DANGER Hydrogen gas is flammable. Eliminate all ignition sources. Do not place an ignition source within 25 feet of this unit. DO NOT SMOKE WITHIN A 25 FOOT RADIUS OF THE FUEL CELL.

Figure 100. Fan connectors

Tools required Nuvera part number

Description

Qty.

N/A

hex head keys

1 set

N/A

socket set

1 set

N/A

socket wrench

1

1.

FAN CONNECTOR

2.

CATHODE FAN CONNECTOR

4.

Use the 7 mm socket wrench or flat head screwdriver to loosen the hose clamps from the hoses. Disconnect the hoses.

5.

Disconnect pitot tube.

• For fuel cell systems up to and including S/N A2D1S01500R, see Figure 101.

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Service procedures

• For fuel cell systems S/N A2D1S01501R and after, see Figure 102.

Figure 102. Radiator mounting, fuel cell systems S/N A2D1S01501R and after

Figure 101. Radiator mounting, fuel cell systems up to and including S/N A2D1S01500R

1.

CAPSCREW

4.

PITOT ASSEMBLY

1.

CAPSCREW

5.

RADIATOR

2.

5.

RADIATOR

2.

WASHER

6.

PITOT TUBE

3.

PITOT TUBE

6.

3.

LOWER MOUNTING BRACKET

UPPER MOUNTING BRACKET

LOWER MOUNTING BRACKET

4.

PITOT ASSEMBLY

7.

UPPER MOUNTING BRACKET

6.

Loosen the two bolts and washers on the upper radiator bracket. See Figure 101.

7.

Remove the upper radiator bracket. See Figure 101.

8.

Loosen the two capscrews connecting the lower mounting bracket to the bottom sled plate. See Figure 103.

9.

Remove the grounding wire from the back side of the radiator.

10. Use the 7 mm socket wrench or flat head screwdriver to loosen the hose clamps on the hoses to the radiator and charged air intercooler.

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Service procedures

Clean

11. Hold the lower mounting bracket against the bottom of the radiator, and lightly pull the radiator away from fuel cell to detach from hoses and remove. See Figure 104.

Blow the entire radiator with compressed air to clean.

Install 1.

Lift the radiator up from work station making sure to hold the bottom mounting bracket against the bottom of the radiator.

2.

Align the radiator with the hoses on the fuel cell system. Push the radiator until all ports are in the hoses and bottom mounting bracket is in place. See Figure 104.

3.

Install upper radiator bracket onto the radiator. Tighten the screws to 25.6 N•m (19 lbf ft.).

Figure 103. Bottom radiator mounting bracket 1.

CAPSCREWS

3.

SLED PLATE

2.

LOWER MOUNTING BRACKET

4.

RADIATOR

• For fuel cell systems up to and including S/N A2D1S01500R, see Figure 101.

• For fuel cell systems S/N A2D1S01501R and after, see Figure 102.

4.

Tighten the two bolts holding the bottom mounting bracket against the bottom sled plate to 25.6 N•m (19 lbf ft.).

5.

Connect Pitot tube to Pitot assembly.

• For fuel cell systems up to and including S/N A2D1S01500R, see Figure 101.

• For fuel cell systems S/N A2D1S01501R and after, see Figure 102.

6.

Use the 7 mm socket wrench or flat head screwdriver to tighten all hose clamps.

7.

Connect fan connectors. See Figure 100.

8.

After radiator is installed, check the fan to make sure it spins freely. See Figure 105.

Figure 104. Remove radiator 12. Transfer the radiator to work station.

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Nuvera® Fuel Cell System C95A-33 Service Manual

Service procedures

used. If you feel that you are not qualified to perform this procedure, contact Nuvera Fuel Cells LLC. 3.

Use caution when handling all parts in the fuel cell, as they may contain compressed hydrogen gas.

DANGER Hydrogen gas is flammable. Eliminate all ignition sources. Do not place an ignition source within 25 feet of this unit. DO NOT SMOKE WITHIN A 25 FOOT RADIUS OF THE FUEL CELL.

Figure 105. Check radiator fan clearance 9.

Parts and materials required

Install the engine sled back into fuel cell. See Removing and installing the engine sled.

Nuvera part number

Description

Qty.

N/A

2 mm hex key

1

N/A

Digital Volt Meter (DVM)

1

N/A

Very small flathead screwdriver

1

To remove the Differential Pressure Switch (DPS) and replace with new. To set and adjust the DPS.

N/A

NFCSST and laptop

1

Safety and warnings

N/A

Orange Hyster cable and either Kavaser or IFAK

1

10. Perform anode loop leak check. See Leak check anode loop.

11. Refill the radiator with Propylene Glycol coolant. See Draining and filling coolant.

Replacing the DPS (fuel cell systems up to and including S/N A2D1S01500R)

Scope

NOTE: Do not perform this procedure unless you have fully read and understand this document.

1.

2.

Read this manual and other specified documentation in their entirety before servicing this equipment.

Before performing this procedure, ensure that you have the proper skill and specialty training needed to perform this procedure as it applies to both the Nuvera® Fuel Cell System and all supplemental equipment

81

Remove 1.

Confirm ultracapacitors are discharged. See Discharging and recharging the ultracapacitors.

2.

Remove the air filter cover. See Replacing the air filter.

3.

See Set up for external supply of nominal bus voltage. www.nuvera.com

Nuvera® Fuel Cell System C95A-33 Service Manual

Service procedures

4.

Replacing the DPS (fuel cell systems S/N A2D1S01501R and after)

Use the 2 mm hex key to remove the four screws attaching the DPS to the frame. See Figure 106.

Scope To remove the Differential Pressure Switch (DPS) and replace with new.

Safety and warnings NOTE: Do not perform this procedure unless you have fully read and understand this document.

1.

Read this manual and other specified documentation in their entirety before servicing this equipment.

2.

Before performing this procedure, ensure that you have the proper skill and specialty training needed to perform this procedure as it applies to both the Nuvera® Fuel Cell System and all supplemental equipment used. If you feel that you are not qualified to perform this procedure, contact Nuvera Fuel Cells LLC.

3.

Use caution when handling all parts in the fuel cell, as they may contain compressed hydrogen gas.

Figure 106. DPS 1.

HOSE

3.

LOW PRESSURE HOSE

2.

MOUNTING SCREWS

4.

TERMINAL LEADS

5.

Gently remove the blue hoses from each end of the DPS. See Figure 106.

Install 1.

Insert terminals back into DPS. See Figure 106.

2.

Connect the two hoses back to the DPS. See Figure 106.

3.

Insert the two mounting screws into the DPS and attach the DPS back onto the radiator cover. Use the 2 mm hex key to tighten.

4.

Re-install the main cover. See Replacing the air filter.

5.

Recharge the ultracapacitors. See Discharging and recharging the ultracapacitors.

DANGER Hydrogen gas is flammable. Eliminate all ignition sources. Do not place an ignition source within 25 feet of this unit. DO NOT SMOKE WITHIN A 25 FOOT RADIUS OF THE FUEL CELL.

Parts and materials required

82

Nuvera part number

Description

Qty.

N/A

2 mm hex key

1

N/A

Digital Volt Meter (DVM)

1

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Nuvera® Fuel Cell System C95A-33 Service Manual

Service procedures

6.

Disconnect the terminals.

7.

Remove DPS.

Qty.

N/A

Very small flathead screwdriver

1

N/A

NFCSST and laptop

1

N/A

Orange Hyster cable and either Kavaser or IFAK

NOTE: Any restriction across the radiator will affect the differential pressure produced by the ventilation fan flow, and must be minimized.

1

1.

Ensure radiator fins are clean. Blow out with compressed air if necessary.

2.

Jump out the DPS switch circuit by removing the two wire terminals from their contacts and connecting them together. Secure and insulate using electrical tape.

3.

Use the Nuvera Fuel Cell System Service Tool (NFCSST) to Start into off mode.

Adjust the DPS

Confirm ultracapacitors are discharged. See Discharging and recharging the ultracapacitors.

2.

Remove the main cover. See Removing and installing the main cover.

3.

Set up for external supply of nominal bus voltage

4.

Use the 2 mm hex key to remove the two mounting screws. See Figure 107.

• This will automatically set the fan to run at its default speed of 40%.

Figure 107. DPS 1.

Gently remove the two blue hoses from each end of the DPS. See Figure 107.

Description

Remove 1.

5.

Nuvera part number

HOSES

2.

4.

Use a digital multimeter, set to measure resistance/continuity, to probe the two contacts of the DPS.

5.

Slowly turn DPS adjustment screw counterclockwise (towards the "+") until the multimeter reads an open circuit.

6.

Then, slowly turn DPS adjustment screw back clockwise (towards the "-") until the multimeter consistently reads closed circuit.

7.

Use automated procedure within NFCS Service Tool to "Stop System".

8.

Ensure DPS becomes dissatisfied and the multimeter reads an open circuit again within 5 seconds.

9.

Reinstall wires with spade terminals onto the DPS contacts.

Install

CAPCSCREWS

1.

83

Install DPS.

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Nuvera® Fuel Cell System C95A-33 Service Manual

Service procedures

2.

Insert terminals back into DPS.

3.

Connect the two hoses back to the DPS. See Figure 107.

4.

Insert the two mounting screws into the DPS and attach the DPS back onto the radiator cover. Use the 2 mm hex key to tighten. See Figure 107.

5.

Re-install the main cover. See Removing and installing the main cover.

6.

Recharge ultracapacitors. See Discharging and recharging the ultracapacitors.

3.

Use caution when handling all parts in the fuel cell, as they may contain compressed hydrogen gas.

DANGER Hydrogen gas is flammable. Eliminate all ignition sources. Do not place an ignition source within 25 feet of this unit. DO NOT SMOKE WITHIN A 25 FOOT RADIUS OF THE FUEL CELL.

Tools required Nuvera part number

Description

Qty.

N/A

4 mm, 5mm, 8mm hex keys

1 ea.

N/A

7 mm wrench

1

To remove and install the air compressor.

N/A

1

Safety and warnings

Flat head screwdriver

N/A

Pliers

1

Replacing the air compressor (fuel cell systems up to and including S/ NA2D1S01500R)

Scope

NOTE: Do not perform this procedure unless you have fully read and understand this document.

1.

Read this manual and other specified documentation in their entirety before servicing this equipment.

2.

Before performing this procedure, ensure that you have the proper skill and specialty training needed to perform this procedure as it applies to both the Nuvera® Fuel Cell System and all supplemental equipment used. If you feel that you are not qualified to perform this procedure, contact Nuvera Fuel Cells LLC.

NOTE: This tool list does not include tools needed for additional procedures that may be needed for this service. Check the procedures listed below for all tools needed.

Prepare Before removing the air compressor, the following procedures must be performed: 1.

Preparing the Nuvera fuel cell system for service

2.

Discharging and recharging the ultracapacitors.

Remove 1.

84

Remove the main cover. See Removing and installing the main cover.

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Nuvera® Fuel Cell System C95A-33 Service Manual

Service procedures

2.

Confirm all hydrogen fuel has been vented.

See Vent hydrogen from engine plumbing lines.

3.

Remove the engine sled from the fuel cell system. See Removing and installing the engine sled.

4.

Remove the radiator from the engine sled.

See Removing and installing the radiator.

5.

Once the previous steps have been performed, cut the tie wrap attaching the compressor motor to the cable guard. See Figure 108.

7.

Use the 7 mm socket wrench or flat head screwdriver to loosen the hose clamp on the front of the three-way valve hose. Remove the hose. See Figure 108.

8.

Use the 4 mm hex key to remove the bolts attaching the coolant filter bracket to the crossmember. Remove the coolant filter. See Figure 109.

9.

Use the 4 mm hex key to remove the bolts attaching the fuse box to the crossmember.

Remove the fuse box. See Figure 109.

Figure 109. Coolant filter and fuse box 1.

BOLT

2.

COOLANT FILTER

3.

FUSE BOX

10. Use the 4 mm hex key to remove the bolts attaching the fuse box to the crossmember.

Remove the fuse box. See Figure 109.

11. Use the 4 mm hex key to remove the timers from the compressor frame. Leave wires connected. See Figure 110.

Figure 108. Cable guard 1.

TIE WRAP

3.

10 MM NUT

2.

CABLE GUARD

4.

HOSE CLAMP

6.

Use the 10 mm wrench to remove the two nuts attaching the cable guard to the air compressor (Figure 108). Remove the cable guard.

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Nuvera® Fuel Cell System C95A-33 Service Manual

Service procedures

Figure 111. Compressor to air cooler hose 1.

HOSE CLAMP

2.

HOSE

15. Disconnect the leads from the 24V battery system. See Figure 112.

Figure 110. Vent OK timer bolt 12. Disconnect the electrical connector from the three-way valve.

13. Pull the electrical harness out and down through the compressor frame and out the front of the engine sled.

14. Use the 7 mm socket wrench or flat head screwdriver to loosen the hose clamp on the compressor to air cooler hose. Remove hose.

See Figure 111.

Figure 112. Disconnect batteries 1.

LEADS

3.

BRACKET

2.

BATTERIES

4.

CAPSCREWS

16. Use the 2.5 mm hex key to remove the bolts on the battery bracket (Figure 112). Remove the batteries.

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Service procedures

17. Locate the two relays attached to the left side of the frame and remove the relays. Use the 4 mm hex key to loosen the bolts attaching each relay mount to the frame. Remove the relay mounts.

Figure 114. Mounting bolts 1.

RELAY

2.

RELAY MOUNT

3.

2.

FRAME TO WALL MOUNTING BOLTS

19. Use the 7 mm socket wrench or flat head screwdriver to loosen the hose clamp from the coolant pump intake hose. Remove hose.

See Figure 115.

Figure 113. Relays 1.

BATTERY BOX MOUNTING BOLTS

MOUNTING BOLT

18. Use the 4 mm hex key to remove the five flat head hex bolts attaching the battery tray to the back wall. Lift the battery tray up and out to remove. See Figure 114.

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Service procedures

Figure 115. Coolant pump intake hose 1.

HOSE CLAMP

2.

COOLANT PUMP INLET HOSE

20. Use the 5 mm hex key to remove the five flat head hex bolts attaching the frame to the back wall. See Figure 114.

Figure 116. Compressor frame bolts

21. Use a 8 mm socket drive ball head wrench and 3/8 ratchet to remove the bolts attaching the compressor frame to the engine sled. See Figure 116.

22. Gently pull compressor frame forward checking for any binding or pulling on the harness, hoses or loose cables until you are able to reach behind the compressor. Unplug both of the compressor electrical connectors.

23. Locate the four bolts attaching the compressor to the compressor frame (Figure 117). Use the 5 mm hex key to remove the bolts.

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Nuvera® Fuel Cell System C95A-33 Service Manual

Service procedures

Install 1.

Install the new compressor, motor, and airbox assembly into the engine sled.

NOTE: Apply threadlocker to all fasteners.

Figure 117. Compressor mounting bolts 24. Locate the two bolts attaching the compressor motor to the motor mount (Figure 118). Use the 5 mm hex key to remove the bolts.

2.

Insert the two bolts attaching the compressor motor to the motor mount. Use the 5 mm hex key to tighten the bolts. See Figure 118.

3.

Insert the four bolts attaching the compressor to the compressor frame. Use the 5 mm hex key to remove the bolts. See Figure 117.

4.

Gently pull compressor frame forward checking for any binding or pulling on the harness, hoses or loose cables until you are able to reach behind the compressor.

Connect both of the compressor electrical connectors to the main wire harness.

5.

Insert the bolts attaching the compressor frame to the engine sled. Use an 8 mm socket drive ball head wrench and 3/8 ratchet to tighten bolts. See Figure 116.

Torque M8 bolts to 20-25 N•m.

Figure 118. Compressor motor 25. At this point the compressor, motor, and airbox assembly can be removed from the engine sled.

89

6.

Insert the five hex bolts to attach the frame to the back wall. Use the 5 mm hex key to tighten. See Figure 114.

7.

Fit the hose clamp back on to the coolant pump intake hose and install the hose. Use the 7 mm socket wrench or flat head screwdriver to tighten the hose clamp. See Figure 115.

8.

Install the battery tray into the engine sled and insert the five flat head hex bolts to attach the battery tray to the back wall. Use the 4 mm hex key to tighten. See Figure 114.

9.

Install the two relay mounts and insert the bolts attaching each relay mount to the frame. Use the 4 mm hex key to tighten the bolts. Insert the relays into the relay mounts.

See Figure 113. www.nuvera.com

Nuvera® Fuel Cell System C95A-33 Service Manual

Service procedures

10. Install the batteries into the battery tray.

Install the battery hold down bracket and insert the two bolts to attach the bracket.

Use the 2.5 mm hex key to tighten the bolts.

See Figure 112.

22. Perform anode loop leak check. See Leak check anode loop.

23. Re-install the main cover. See Removing and installing the main cover.

11. Connect the leads to the batteries. See Figure 112.

12. Fit the hose clamp back on the compressor to air cooler hose and install the hose. Use the 7 mm socket wrench or flat head screwdriver to tighten the hose clamp. Figure 111.

13. Feed the main electrical harness back into the engine sled and connect to the connector on the three-way valve.

14. Install the timers back onto the compressor frame. Insert the bolt in the middle of the timer. Use the 4 mm hex key to tighten. See Figure 110.

24. Recharge the ultracapacitors. See Discharging and recharging the ultracapacitorsDischarging and recharging the ultracapacitors.

Replacing the air compressor (fuel cell systems S/N A2D1S01501R and after)

Scope To remove and install the air compressor.

Safety and warnings NOTE: Do not perform this procedure unless you have fully read and understand this document.

15. Install the fuse box and insert the bolts to attach the fuse box to the crossmember. Use the 4 mm hex key to tighten. See Figure 109.

16. Install the coolant filter and insert the bolts to attach the coolant filter bracket to the crossmember. Use the 4 mm hex key to tighten. See Figure 109.

1.

Read this manual and other specified documentation in their entirety before servicing this equipment.

2.

Before performing this procedure, ensure that you have the proper skill and specialty training needed to perform this procedure as it applies to both the Nuvera® Fuel Cell System and all supplemental equipment used. If you feel that you are not qualified to perform this procedure, contact Nuvera Fuel Cells LLC.

3.

Use caution when handling all parts in the fuel cell, as they may contain compressed hydrogen gas.

17. Fit the hose clamp back on the three-way valve hose and install the hose. Use the 7 mm socket wrench or flat head screwdriver to tighten the hose clamp. See Figure 108.

18. Install the cable guard and insert the nuts to attach the cable guard to the air compressor.

Use the 10 mm wrench to tighten the nuts.

See Figure 108.

19. Use a new tie-wrap to attach the cable motor to the compressor guard. See Figure 108.

20. Install the radiator back on to the engine sled.

See Removing and installing the radiator.

21. Install the engine sled back into the fuel cell system. See Removing and installing the engine sled.

90

DANGER Hydrogen gas is flammable. Eliminate all ignition sources. Do not place an ignition source within 25 feet of this unit. DO NOT SMOKE WITHIN A 25 FOOT RADIUS OF THE FUEL CELL.

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Nuvera® Fuel Cell System C95A-33 Service Manual

Service procedures

Tools required

5.

Nuvera part number

Description

Qty.

N/A

3 mm, 4 mm, 5 mm hex keys

1 ea.

N/A

7 mm wrench

1

N/A

13 mm wrench

1

N/A

Flat head screwdriver

1

N/A

Pliers

1

Once the previous steps have been performed, cut the tie wrap attaching the compressor motor to the cable guard. See Figure 119.

NOTE: This tool list does not include tools needed for additional procedures that may be needed for this service. Check the procedures listed below for all tools needed.

Prepare Before removing the compressor, the following procedures must be performed: 1.

Preparing the Nuvera fuel cell system for service.

2.

Discharging and recharging the ultracapacitors.

Figure 119. Cable guard

Remove 1.

Remove the main cover. See Removing and installing the main cover.

2.

Confirm all hydrogen fuel has been vented.

See Vent hydrogen from engine plumbing lines.

3.

Remove the engine sled from the fuel cell system. See Removing and installing the engine sled.

4.

Remove the radiator from the engine sled.

See Removing and installing the radiator.

91

1.

TIE WRAP

3.

10 MM NUT

2.

CABLE GUARD

4.

HOSE CLAMP

6.

Use the 10 mm wrench to remove the two nuts attaching the cable guard to the air compressor (Figure 119). Remove the cable guard.

7.

Use the 7 mm socket wrench or flat head screwdriver to loosen the hose clamp on the front of the three-way valve hose. Remove the hose. See Figure 119.

8.

Use the 4 mm hex key to remove the bolts and washers attaching the coolant filter bracket to the crossmember. Remove the coolant filter. See Figure 120. www.nuvera.com

Nuvera® Fuel Cell System C95A-33 Service Manual

Service procedures

9.

Figure 120. Coolant filter and bracket

Figure 122. Compressor to air cooler hose

Use the 4 mm hex key to remove the bolts and washers attaching the fuse box bracket to the crossmember. Remove the fuse box.

See Figure 121.

13. Remove the compressor motor mount bolts from the mounting clamp. See Figure 123.

Figure 123. Compressor mounting clamp 14. Remove the two bolts holding the compressor to the upper frame of the engine sled with an open-end wrench. See Figure 124.

Figure 121. Fuse box bracket 10. Disconnect the electrical connector from the three-way valve.

15. Remove the two bolts holding the compressor to the lower frame of the engine sled with an open-end wrench. See Figure 125.

11. Pull the electrical harness out and down through the compressor frame and out the front of the engine sled.

12. Use the 7 mm socket wrench or flat head screwdriver to loosen the hose clamp from the coolant pump intake and pull hose free.

See Figure 122.

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Nuvera® Fuel Cell System C95A-33 Service Manual

Service procedures

Figure 126. Service panel 17. Reach into the unit to unplug the two compressor connectors. See Figure 127.

Figure 124. Upper frame bolts

Figure 125. Lower frame bolts 16. Use the 3 mm hex wrench to remove the service panel from the back wall. See Figure 126.

Figure 127. Compressor connectors

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Nuvera® Fuel Cell System C95A-33 Service Manual

Service procedures

18. Locate the four bolts attaching the compressor to the compressor frame (Figure 128). Use the 5 mm hex key to remove the bolts.

able to reach behind the compressor.

Connect both of the compressor electrical connectors to the main wire harness. See Figure 127.

Figure 128. Compressor mounting bolts

4.

Insert the three bolts into the service panel and install the service panel to the back wall.

Use the 3 mm hex wrench to tighten the bolts. See Figure 126.

5.

Insert the two bolts to attach the compressor to the lower frame of the engine sled. Use the open-end wrench to tighten. See Figure 125.

6.

Insert the two bolts to attach the compressor to the upper frame of the engine sled. Use the open-end wrench to tighten.

7.

Insert the two bolts into the compressor motor mount. Use the 4 mm hex key to tighten. See Figure 123.

8.

Fit the hose clamp back on the compressor to air cooler hose and install the hose. Use the 7 mm socket wrench or flat head screwdriver to tighten the hose clamp. Figure 122.

9.

Feed the main electrical harness back into the engine sled and connect to the connector on the three-way valve.

19. At this point the compressor, motor, and airbox assembly can be removed from the engine sled.

10. Install the fuse box and insert the bolts to attach the fuse box to the crossmember. Use the 4 mm hex key to tighten. See Figure 121.

Install

11. Install the coolant filter and insert the bolts to attach the coolant filter bracket to the crossmember. Use the 4 mm hex key to tighten. See Figure 120.

1.

Install the new compressor, motor, and airbox assembly into the engine sled.

12. Fit the hose clamp back on the three-way valve hose and install the hose. Use the 7 mm socket wrench or flat head screwdriver to tighten the hose clamp. See Figure 119.

NOTE: Apply threadlocker to all fasteners.

2.

3.

Insert the four bolts attaching the compressor to the compressor frame. Use the 5 mm hex key to tighten the bolts. See Figure 128.

13. Install the cable guard and insert the nuts to attach the cable guard to the air compressor.

Use the 10 mm wrench to tighten the nuts.

See Figure 119.

Gently push compressor frame inward checking for any binding or pulling on the harness, hoses or loose cables until you are 94

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Nuvera® Fuel Cell System C95A-33 Service Manual

Service procedures

14. Use a new tie-wrap to attach the cable motor to the compressor guard. See Figure 119.

3.

15. Install the radiator back on the engine sled.

See Removing and installing the radiator.

Use caution when handling all parts in the fuel cell, as they may contain compressed hydrogen gas.

DANGER

16. Install the engine sled back into the fuel cell system. See Removing and installing the engine sled.

Hydrogen gas is flammable. Eliminate all ignition sources. Do not place an ignition source within 25 feet of this unit. DO NOT SMOKE WITHIN A 25 FOOT RADIUS OF THE FUEL CELL.

17. Perform a leak check of the Anode Loop. See Leak check anode loop.

18. Re-install the main cover. See Removing and installing the main cover.

Tools required

19. Recharge the ultracapacitors. See Discharging and recharging the ultracapacitors.

Replacing the main fan relay

Nuvera part number

Description

Qty.

N/A

3 mm, 4 mm, 5 mm, 6 mm, 3/16" hex keys

1 ea.

N/A

11/16", 3/4", 5/8", 5.5 mm, 7 mm,13 mm wrenches

1 ea.

N/A

Pliers

1

N/A

Lifting kit

1

Scope To remove and replace the main fan relay

Safety and warnings NOTE: Do not perform this procedure unless you have fully read and understand this document.

1.

Read this manual and other specified documentation in their entirety before servicing this equipment.

2.

Before performing this procedure, ensure that you have the proper skill and specialty training needed to perform this procedure as it applies to both the Nuvera® Fuel Cell System and all supplemental equipment used. If you feel that you are not qualified to perform this procedure, contact Nuvera Fuel Cells LLC.

NOTE: This tool list does not include tools needed for additional procedures that may be needed for this service. Check the procedures listed below for all tools needed.

Prepare Before removing the main fan relay, the following procedures must be performed:

95

1.

Preparing the Nuvera fuel cell system for service

2.

Discharging and recharging the ultracapacitors

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Nuvera® Fuel Cell System C95A-33 Service Manual

Service procedures

Remove 1.

Remove the main cover. See Removing and installing the main cover.

2.

Confirm all hydrogen has been removed from system. See Vent hydrogen from engine plumbing lines.

3.

Remove the engine sled from the fuel cell system. See Removing and installing the engine sled.

NOTE: Follow the procedures in Step 4. through Step 9. for fuel cell systems up to and including .

For fuel cell systems and after, see Step 10. through Step 16.

4.

Figure 130. Main fan relay

Locate the red fan relay. See Figure 129.

1.

MOUNTING BOLT

3.

5.5 MM NUT

2.

7 MM NUT

6.

Use the 7 mm socket and wrench to loosen the two nuts connecting the wire harness to the A1 and A2 terminals (2, Figure 130).

7.

Use the socket and wrench to loosen the two nuts connecting the wire harness to the X1 and X2 terminals (3, Figure 130).

8.

Disconnect wires and remove the main fan relay.

NOTE: Perform the following procedures for fuel cell systems and after.

9.

Loosen and remove the three capscrews attaching the electrical panel to the main bracket. Remove the electrical panel. See Figure 131.

Figure 129. Main fan relay location, fuel cell systems up to and including 5.

Use the 3 mm hex key to remove the two mounting bolts attaching the relay to the fuel cell system (1, Figure 130).

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Figure 132. Main fan relay

ELECTRICAL PANEL

3.

FAN RELAY

2.

SCREW

4.

CAPSCREW

MOUNTING BOLT

2.

7 MM NUT

3.

5.5 MM NUT

13. Use the socket and wrench to loosen the two nuts connecting the wire harness to the X1 and X2 terminals (3, Figure 132).

Figure 131. Remove electrical panel, fuel cell systems and after 1.

1.

14. Disconnect wires and remove the main fan relay.

Install 10. Locate the red fan relay.

11. Use the 3 mm hex key to remove the two mounting bolts attaching the relay to the electrical panel. See Figure 131.

12. Use the 7 mm socket and wrench to loosen the two nuts connecting the wire harness to the A1 and A2 terminals (2, Figure 132).

1.

Locate new relay and connect wires to terminals.

2.

Tighten the two nuts connecting the wire harness to the X1 and X2 terminals (3, Figure 130).

3.

Use the 7 mm socket and wrench to tighten the two nuts connecting the wire harness to the A1 and A2 terminals (2, Figure 130).

4.

Insert the two mounting bolts attaching the relay to the fuel cell system. Use the 3 mm hex key to tighten the bolts. (1, Figure 130).

• For fuel cell systems up to and including , see Figure 129.

• For fuel cell systems and after, see Figure 131.

5.

97

Install the engine sled back into the fuel cell system. See Removing and installing the engine sled. www.nuvera.com

Nuvera® Fuel Cell System C95A-33 Service Manual

Service procedures

6.

Perform a leak check of the Anode Loop. See Leak check anode loop.

7.

Re-install the main cover. See Removing and installing the main cover.

8.

Recharge the ultracapacitors. See Discharging and recharging the ultracapacitors.

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Service procedures

Replacing the humidifier bypass valve

NOTE: This tool list does not include tools needed for additional procedures that may be needed for this service. Check the procedures listed below for all tools needed.

Scope To remove and install the humidifier bypass valve.

Prepare

Safety and warnings NOTE: Do not perform this procedure unless you have fully read and understand this document.

1.

2.

3.

Read this manual and other specified documentation in their entirety before servicing this equipment.

Before performing this procedure, ensure that you have the proper skill and specialty training needed to perform this procedure as it applies to both the Nuvera® Fuel Cell System and all supplemental equipment used. If you feel that you are not qualified to perform this procedure, contact Nuvera Fuel Cells LLC.

Before removing the humidifier bypass valve, the following procedures must be performed: 1.

Preparing the Nuvera fuel cell system for service

2.

Discharging and recharging the ultracapacitors

Remove

Use caution when handling all parts in the fuel cell, as they may contain compressed hydrogen gas.

DANGER Hydrogen gas is flammable. Eliminate all ignition sources. Do not place an ignition source within 25 feet of this unit. DO NOT SMOKE WITHIN A 25 FOOT RADIUS OF THE FUEL CELL.

1.

Remove the main cover. See Removing and installing the main cover.

2.

Confirm all hydrogen fuel has been vented and remove the engine sled from the fuel cell system. See Removing and installing the engine sled.

3.

Remove the radiator from the engine sled.

See Removing and installing the radiator.

4.

After the previous steps have been performed, locate the humidifier valve.

• For fuel cell systems up to and including S/N A2D1S01500R, see Figure 133.

• For fuel cell systems S/N A2D1S01501R and after, see Figure 134.

Tools required Nuvera part number

Description

Qty.

N/A

4 mm hex key

1

N/A

7 mm wrench or flat head screwdriver

1

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Service procedures

5.

Use a flat head screwdriver or 7 mm wrench to loosen the four hose clamps holding the air hose to the humidifier valve, mass airflow sensor, and manifold.

6.

Disconnect the bypass adapter hose from the manifold, humidifier, and mass airflow sensor.

• For fuel cell systems up to and including S/N A2D1S01500R, see Figure 133.

• For fuel cell systems S/N A2D1S01501R and after, see Figure 134.

7.

Remove the bypass adapter hose from the unit.

8.

Disconnect the map adapter hose on the other end of the mass airflow sensor and remove sensor.

Figure 133. Humidifier valve hose, fuel cell systems up to and including S/N A2D1S01500R 1.

HUMIDIFIER VALVE

4.

BYPASS ADAPTER HOSE

2.

MASS AIRFLOW SENSOR

5.

MAP ADAPTER HOSE

3.

HOSE CLAMPS

6.

MANIFOLD

• For fuel cell systems up to and including S/N A2D1S01500R, see Figure 133.

• For fuel cell systems S/N A2D1S01501R and after, see Figure 134.

9.

Use the 4 mm hex key to remove the four bolts attaching the humidifier valve to the manifold. See Figure 135.

Figure 134. Humidifier valve hose, fuel cell systems S/N A2D1S01501R and after 1.

HUMIDIFIER VALVE

4.

BYPASS ADAPTER HOSE

2.

MASS AIRFLOW SENSOR

5.

MAP ADAPTER HOSE

3.

HOSE CLAMPS

6.

MANIFOLD

Figure 135. Humidifier valve 1.

100

HUMIDIFIER VALVE

2.

BOLT

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Service procedures

10. Disconnect the main wire harness connector from the humidifier valve and remove the valve from the manifold.

• For fuel cell systems up to and including S/N A2D1S01500R, see Figure 133.

• For fuel cell systems S/N A2D1S01501R and after, see Figure 134.

11. Inspect the O-ring from the manifold for damage. See Figure 136.

6.

Install the radiator back on to the engine sled.

See Removing and installing the radiator.

7.

Install the engine sled back into the fuel cell system and perform a leak check of the Anode Loop. See Removing and installing the engine sled.

8.

Re-install the main cover. See Removing and installing the main cover.

9.

Recharge the ultracapacitors. See Discharging and recharging the ultracapacitors.

10. Perform automated procedure to confirm functionality of new humidifier bypass valve.

Figure 136. Humidifier valve o-ring

Install 1.

Install the new humidifier valve to the manifold and attach the four bolts. See Figure 135.

2.

Use the 4 mm hex key to tighten the bolts.

See Figure 135.

3.

Connect the main wire harness to the humidifier valve.

4.

Attach the mass airflow sensor to the map adapter hose. Use the flat head screwdriver or 7 mm wrench to tighten hose clamp.

• For fuel cell systems up to and including S/N A2D1S01500R, see Figure 133.

• For fuel cell systems S/N A2D1S01501R and after, see Figure 134.

5.

Install the bypass adapter hose and attach to the mass airflow sensor, humidifier valve, and manifold. Tighten hose clamps.

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Service procedures

Prepare

Replacing the trican sensor

Scope

Before removing the trican sensor, the following procedures must be performed:

To remove and install the trican sensor.

1.

Discharging and recharging the ultracapacitors

2.

Removing and installing the main cover

3.

Vent hydrogen from engine plumbing lines

4.

Removing and installing the engine sled

5.

Replacing the DC/DC unit

Safety and warnings NOTE: Do not perform this procedure unless you have fully read and understand this document.

1.

Read this manual and other specified documentation in their entirety before servicing this equipment.

2.

Before performing this procedure, ensure that you have the proper skill and specialty training needed to perform this procedure as it applies to both the Nuvera® Fuel Cell System and all supplemental equipment used. If you feel that you are not qualified to perform this procedure, contact Nuvera Fuel Cells LLC.

3.

Remove 1.

Confirm ultracapacitors are discharged. See Discharging and recharging the ultracapacitors.

2.

Remove the main cover. See Removing and installing the main cover.

3.

Use caution when handling all parts in the fuel cell, as they may contain compressed hydrogen gas.

Remove the engine sled from the fuel cell system. See Removing and installing the engine sled.

4.

Remove the DC/DC unit from the engine sled.

See Replacing the DC/DC unit.

DANGER

5.

Locate the trican sensor on the lower manifold. See Figure 137.

Hydrogen gas is flammable. Eliminate all ignition sources. Do not place an ignition source within 25 feet of this unit. DO NOT SMOKE WITHIN A 25 FOOT RADIUS OF THE FUEL CELL.

Tools required Nuvera part number

Description

Qty.

N/A

4 mm hex key

1

NOTE: This tool list does not include tools needed for additional procedures that may be needed for this service. Check the procedures listed below for all tools needed.

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Service procedures

7.

Perform anode loop leak check. See Leak check anode loop.

8.

Recharge the ultracapacitors. See Discharging and recharging the ultracapacitors.

Figure 137. Trican sensor 1.

MANIFOLD

3.

BOLT

2.

SENSOR

6.

Disconnect the main wire harness from the trican sensor.

7.

Use the 4 mm hex key to remove the two bolts holding the trican in place. See Figure 137.

8.

Gently remove the trican sensor from the manifold.

Install 1.

Install the trican sensor to the manifold and attach the two bolts. See Figure 137.

2.

Use the 4 mm hex key to tighten the bolts.

See Figure 137.

3.

Connect the main wire harness to the trican sensor.

4.

Install the DC/DC unit. See Replacing the DC/DC unit.

5.

Install the engine sled back into the fuel cell system. See Removing and installing the engine sled.

6.

Re-install the main cover. See Removing and installing the main cover.

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Service procedures

Replacing the three-way valve (fuel cell systems up to and including S/N A2D1S01500R)

Scope

Remove 1.

Remove the main cover. See Removing and installing the main cover.

2.

Confirm all hydrogen has been removed from system. See Vent hydrogen from engine plumbing lines.

3.

Remove the engine sled from the fuel cell system. See Removing and installing the engine sled.

4.

Drain all coolant from the system. See Draining and filling coolant.

5.

Remove the radiator from the fuel cell system. See Removing and installing the radiator.

6.

With the radiator now removed, locate the three-way valve. See Figure 138.

To remove and replace the three-way valve.

Tools required Nuvera part number

Description

Qty.

N/A

4 mm, 5 mm

1 ea.

N/A

11/16", 3/4", 5/8", 13 mm wrenches

1 ea.

N/A

Pliers

1

N/A

Lifting kit

1

NOTE: This tool list does not include tools needed for additional procedures that may be needed for this service. Check the procedures listed below for all tools needed.

Parts/Materials required Nuvera part number

Description

Qty.

N/A

Three-way valve

1

Prepare Before removing the three-way valve, the following procedures must be performed: 1.

Preparing the Nuvera fuel cell system for service

2.

Discharging and recharging the ultracapacitors

Figure 138. Three way valve 1.

HOSE CLAMPS

7.

Disconnect the electrical connection. See Figure 139.

104

2.

THREE-WAY VALVE

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Service procedures

7.

Install the engine sled back into the fuel cell system. See Removing and installing the engine sled.

8.

Perform anode loop leak check. See Leak check anode loop.

9.

Re-install the main cover. See Removing and installing the main cover.

10. Recharge the ultracapacitors. See Discharging and recharging the ultracapacitors.

11. Use automated procedure to confirm functionality of new three-way valve.

Figure 139. Three-way valve connector 1.

CONNECTOR

2.

THREE-WAY VALVE

8.

Use the 7 mm nut driver to loosen three hose clamps. Remove the three-way valve. See Figure 138.

Install 1.

Locate new three-way valve. Remove all three protective dust caps from new valve.

2.

Install the new three-way valve and use the 7 mm nut driver to tighten the three hose clamps. See Figure 138.

3.

Connect the electrical connector. See Figure 139.

4.

Install the radiator back into the fuel cell system. See Removing and installing the radiator.

5.

Follow procedure to leak check the coolant loop. See Leak check coolant loop.

6.

Add coolant into the system. See Draining and filling coolant.

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Service procedures

Replacing the three-way valve (fuel cell systems S/N A2D1S01501R and after)

Scope To remove and replace the three-way valve.

Remove 1.

Remove the main cover. See Removing and installing the main cover.

1.

Loosen the two thumb screws on the air box cover and remove. See Figure 140.

Tools required Nuvera part number

Description

Qty.

N/A

4 mm T handle hex head

1

N/A

7 mm socket

1

N/A

Flat-head screwdriver

1

NOTE: This tool list does not include tools needed for additional procedures that may be needed for this service. Check the procedures listed below for all tools needed.

Parts/Materials required Nuvera part number

Description

Qty.

N/A

Three-way valve

1

Figure 140. Air filter cover 2.

Remove the air filter from the air box.

3.

Use the 4 mm T handle hex wrench to remove the four air box mounting bolts. See Figure 141.

Prepare Before removing the three-way valve, the following procedures must be performed: 1.

Preparing the Nuvera fuel cell system for service

2.

Discharging and recharging the ultracapacitors

3.

Drain the coolant. See Draining and filling coolant (systems with vented stack).

Figure 141. Air box mounting bolts 4.

106

Lift out the air box. Lift out the flange and gasket that are under the air box.

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Service procedures

5.

Put a clean lint free rag into the compressor intake to keep debris from entering the compressor.

6.

Use the 4 mm hex key to remove the fuse box mounting bolts. See Figure 142.

Figure 144. Valve hose clamps 10. Disconnect the electrical connector from the three-way valve.

11. Remove the three hoses from the ends of the valve and lift the valve out from the top of the fuel cell system.

Figure 142. Fuse box bracket 7.

Use the 4 mm hex key to remove DI filter mounting bolts. See Figure 143.

Install 1.

Locate new three-way valve. Remove all three protective dust caps from new valve.

2.

Insert the new three-way valve into the fuel cell system. Connect all hoses and use the flat-head screwdriver or 7 mm socket to tighten the hose clamps. See Figure 144.

3.

Connect electrical connections to the threeway valve.

4.

Place the DI filter back into position and insert the bolts into the filter mounting bracket. Use the 4 mm hex key to tighten the bolts. See Figure 143.

5.

Place the fuse box bracket back into position.

Insert the two bolts into the bracket and use the 4 mm hex key to tighten the bolts. See Figure 142.

6.

Re-install the gasket, flange and air box.

Insert the four mounting bolts and use the 4 mm T-handle hex wrench to tighten the bolts.

Torque M5 bolts to 6-8 N•m.

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Figure 143. DI filter bracket 8.

9.

Gently move both the fuse box and DI filter as far out of the way as possible, to allow access to the three-way valve.

Use either the flat-head screwdriver or 7 mm socket, to loosen the three hose clamps on the three-way valve. See Figure 144.

Nuvera® Fuel Cell System C95A-33 Service Manual

Service procedures

7.

Place the air filter back into the air box. See Figure 140.

8.

Insert the two thumb screws into the air filter cover and tighten. See Figure 140.

9.

Perform a coolant loop leak check. See Leak check coolant loop.

10. Refill coolant. See Draining and filling coolant (systems with vented stack).

11. Re-install the main cover. See Removing and installing the main cover.

12. Recharge the ultracapacitors. See Discharging and recharging the ultracapacitors.

13. Use a load bank to test the fuel cell system.

Confirm three-way valve is functioning properly.

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Service procedures

Replacing the water level sensor

Scope To remove and install the water level sensor.

Safety and warnings NOTE: Do not perform this procedure unless you have fully read and understand this document.

1.

Read this manual and other specified documentation in their entirety before servicing this equipment.

2.

Before performing this procedure, ensure that you have the proper skill and specialty training needed to perform this procedure as it applies to both the Nuvera® Fuel Cell System and all supplemental equipment used. If you feel that you are not qualified to perform this procedure, contact Nuvera Fuel Cells LLC.

3.

Use caution when handling all parts in the fuel cell, as they may contain compressed hydrogen gas.

Nuvera part number

Description

Qty.

N/A

11/16", 3/4", 5/8", 1 ½",10 mm, 13 mm wrenches

1 ea.

N/A

Pliers

1

N/A

Lifting kit

1

NOTE: This tool list does not include tools needed for additional procedures that may be needed for this service. Check the procedures listed below for all tools needed.

Prepare Before removing the water level sensor, the following procedures must be performed: 1.

Preparing the truck and removing the fuel cell

2.

Discharging and recharging the ultracapacitors

Remove

DANGER Hydrogen gas is flammable. Eliminate all ignition sources. Do not place an ignition source within 25 feet of this unit. DO NOT SMOKE WITHIN A 25 FOOT RADIUS OF THE FUEL CELL.

Tools required Nuvera part number

Description

Qty.

N/A

4 mm, 5mm, 6mm, 3/16 in. hex keys

1 ea.

1.

Remove the main cover. See Removing and installing the main cover.

2.

Confirm all hydrogen has been removed from system. See Vent hydrogen from engine plumbing lines.

3.

Remove the engine sled from the fuel cell system. See Removing and installing the engine sled.

4.

Locate the water level sensor. See Figure 145.

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Service procedures

Figure 145. Water level sensor 5.

Disconnect the water level sensor from the wire harness.

6.

Remove the water level sensor.

Install 1.

Install new water level sensor. See Figure 145.

2.

Connect the water level sensor to the wire harness.

3.

Install the engine sled back into the fuel cell system. See Removing and installing the engine sled.

4.

Perform anode loop leak check. See Leak check anode loop

5.

Re-install the main cover. See Removing and installing the main cover.

6.

Recharge the ultracapacitors. See Discharging and recharging the ultracapacitors.

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Service procedures

Replacing the fuel cell stack

Scope To remove the fuel cell stack and replace with new.

Nuvera part number

Description

Qty.

N/A

Socket extension tool (6 mm hex head)

1

N/A

Plexi trifecta manifold cover

1

Safety and warnings NOTE: Do not perform this procedure unless you have fully read and understand this document.

1.

Read this manual and other specified documentation in their entirety before servicing this equipment.

2.

Before performing this procedure, ensure that you have the proper skill and specialty training needed to perform this procedure as it applies to both the Nuvera® Fuel Cell System and all supplemental equipment used. If you feel that you are not qualified to perform this procedure, contact Nuvera Fuel Cells LLC.

3.

NOTE: This list does not include tools required for additional service procedures. Check the procedures below for necessary tools.

Parts and materials required

Use caution when handling all parts in the fuel cell, as they may contain compressed hydrogen gas.

Nuvera part number

Description

Qty.

N/A

Fuel cell stack

1

N/A

D-clamps

2

N/A

Tow straps

2

31000050

Ox-Gard antioxidant compound

AR

Prepare

DANGER Hydrogen gas is flammable. Eliminate all ignition sources. Do not place an ignition source within 25 feet of this unit. DO NOT SMOKE WITHIN A 25 FOOT RADIUS OF THE FUEL CELL.

Before removing the fuel cell stack, the following procedures must be performed: 1.

Vent hydrogen from engine plumbing lines

2.

Discharging and recharging the ultracapacitors

Tools required

Remove

Nuvera part number

Description

Qty.

N/A

Socket set

1 set

N/A

Socket wrench

1

N/A

Hex head keys (2.5mm, 4 mm)

1

1.

Remove the main cover from the fuel cell system. See Removing and installing the main cover.

2.

Remove the heater from the condensate tank and drain coolant. See Drain coolant.

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3.

Disconnect the leads from the 24V battery system.

• For fuel cell systems up to and including S/N A2D1S01500R, see Figure 146.

• For fuel cell systems S/N A2D1S01501R and after, see Figure 147.

Figure 147. Disconnect batteries, fuel cell systems S/N A2D1S01501R and after 1.

LEADS

5.

WASHER

2.

BATTERIES

6.

MAIN WIRE HARNESS

3.

BRACKET

7.

BATTERY JUMPER

4.

BOLT

4.

Use the 2.5 mm hex head key to remove the two screws on the cross-bracket. Remove bracket.

5.

Remove batteries.

6.

Use the 4 mm hex head key to remove the three screws from the top of the coolant overflow reservoir. See Figure 148.

7.

Disconnect the overflow tube from the radiator side. Remove the overflow reservoir, making sure there is nothing leaking from the disconnected end of the overflow tube. See Figure 148.

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Figure 146. Disconnect batteries, fuel cell systems up to and including S/N A2D1S01500R 1.

LEADS

3.

BRACKET

2.

BATTERIES

4.

CAPSCREWS

Nuvera® Fuel Cell System C95A-33 Service Manual

Service procedures

Figure 148. Remove/Install overflow reservoir 1.

OVERFLOW RESERVOIR

2.

COOLANT OVERFLOW TUBE

8.

Disconnect the four CVM connectors from the CVM module. See Figure 149.

Figure 150. Battery terminals 10. Disconnect the busbar from the stack positive and negative power extraction tabs. Remove all connected components from extraction tabs. See Figure 151.

Figure 149. CVM connectors 9.

Disconnect the battery terminals from the bottom of the fuel cell stack. See Figure 150.

Figure 151. Busbar 11. Locate the socket extension tool with the 6 mm hex head provided by Nuvera. Attach the extension tool to a socket wrench. See Figure 152.

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Figure 152. Extension tool 12. Use the socket wrench with extension to loosen the six screws at the bottom of the fuel cell stack that attach the stack to the manifold. See Figure 153.

Figure 154. Attach lifting eyes to fuel cell stack 15. Hold the stack with one hand and slowly use the overhead crane to lift the stack up and out of the engine sled, taking care not to damage the stack extraction tabs, positive and negative buss bars, support brackets, or ultracapacitor module tabs. See Figure 155.

Figure 153. Loosen screws with extension tool NOTE: Always use Nuvera approved and ANSI rated lifting eyes, clamps, bolts, and chains.

13. Thread two lifting eyes into holes on the top of the fuel cell stack. Use 15mm socket to torque bolts to 30 N•m (22 lbf ft.).

14. Use D-clamps to connect straps that are attached to an overhead crane, to the lifting eyes. See Figure 154.

Figure 155. Remove stack 16. Move the stack to a clean/clear surface and set it down.

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Service procedures

17. Place the plexi trifecta manifold cover on top of the open manifold to protect from debris.

each screw to 17 N•m (12.5 lbf ft.) until the sequence is finished. Repeat the sequence, this time fully torquing each screw to 34.8 N•m (25.6 lbf ft.). See Figure 156 and Figure 157.

Install NOTE: Before preparing new stack for installation, make sure the front of the stack is facing you. The label should be facing forward and the post should be on your left.

NOTE: Always use Nuvera approved and ANSI rated lifting eyes, clamps, bolts, and chains.

1.

Thread two lifting eyes into holes on the top of the new fuel cell stack. Use 15mm socket to torque bolts to 30 N•m (22 lbf ft.). See Figure 154.

2.

Use D-clamps to connect straps that are attached to an overhead crane, to the lifting eyes. See Figure 154.

3.

Use the overhead crane to lift the stack off the work station and move the stack to the engine sled. See Figure 155.

Figure 156. Torquing sequence

NOTE: Before installing the stack, confirm the manifold gaskets are in place and properly aligned in their grooves. ALWAYS USE NEW MANIFOLD GASKETS. NOTE: When installing the stack into the engine sled, make sure you position the stack directly above the manifold and lower the stack straight down. Do not try to install the stack horizontally, as this may cause the stack to drag on the manifold gasket, causing damage to the gasket.

4.

5.

Very carefully lower the stack down on the manifold and line up the six holes on the bottom of the stack with the holes on the manifold. Take care not to damage the stack extraction tabs, positive and negative buss bars, support brackets, or ultracapacitor module tabs.

Figure 157. Tighten screws with extension tool 6.

Insert the six capscrews to attach the stack to the upper manifold. Use the socket wrench with extension tool to tighten the screws in the following sequence (Figure 156), torquing 115

Attach the negative busbar to the stack negative extraction tab. See Figure 151.

• Connect the back stud with a washer and a nut.

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Nuvera® Fuel Cell System C95A-33 Service Manual

Service procedures

Replacing the humidifier

• Connect the front stud with a washer, the negative wire terminal, washer and nut in that order.

• Tighten all nuts to 30 N•m (22 lbf ft.).

7.

Scope To remove and install the humidifier.

Attach the positive busbar to the stack positive extraction tab. See Figure 151.

Safety and warnings

• Connect the back stud with a washer and a nut.

• Connect the front stud with a washer, the negative wire terminal, washer and nut in that order.

• Tighten all nuts to 30 N•m (22 lbf ft.).

8.

Apply Ox-Gard to positive and negative extraction tabs.

9.

Connect the battery terminals to the bottom of the stack. See Figure 150.

NOTE: Do not perform this procedure unless you have fully read and understand this document.

1.

Read this manual and other specified documentation in their entirety before servicing this equipment.

2.

Before performing this procedure, ensure that you have the proper skill and specialty training needed to perform this procedure as it applies to both the Nuvera® Fuel Cell System and all supplemental equipment used. If you feel that you are not qualified to perform this procedure, contact Nuvera Fuel Cells LLC.

3.

Use caution when handling all parts in the fuel cell, as they may contain compressed hydrogen gas.

10. Connect the four CVM connectors to the CVM module. See Figure 149.

11. Install overflow reservoir. See Figure 148.

12. Connect the radiator overflow tube to the radiator.

13. Install three screws to secure the overflow reservoir and tighten by hand. Do not overtighten, as this may damage overflow reservoir.

DANGER Hydrogen gas is flammable. Eliminate all ignition sources. Do not place an ignition source within 25 feet of this unit. DO NOT SMOKE WITHIN A 25 FOOT RADIUS OF THE FUEL CELL.

14. Attach battery leads.

• For fuel cell systems up to and including S/N A2D1S01500R, see Figure 146.

• For fuel cell systems S/N A2D1S01501R and after, see Figure 147.

15. Perform leak checks. See Leak check coolant loop.

Tools required Nuvera part number

Description

Qty.

17. Install main cover on to fuel cell system. See Removing and installing the main cover.

N/A

Hex key set

1

18. Recharge ultracapacitors. See Recharge the ultracapacitors.

N/A

7 mm wrench or flat head screwdriver

1

16. Refill coolant. See Refill coolant.

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NOTE: This tool list does not include tools needed for additional procedures that may be needed for this service. Check the procedures listed below for all tools needed.

Prepare Before removing the humidifier, the following procedures must be performed: 1.

Preparing the Nuvera fuel cell system for service

2.

Vent hydrogen fuel lines. See Vent hydrogen from engine plumbing lines.

3.

Discharging and recharging the ultracapacitors

Remove 1.

Remove the main cover. See Removing and installing the main cover.

2.

Remove the engine sled from the fuel cell system. See Removing and installing the engine sled.

3.

Remove the radiator from the engine sled.

See Removing and installing the radiator.

4.

Remove the fuel cell stack from the engine sled. See Replacing the fuel cell stack.

5.

Remove the DC/DC unit. See Replacing the DC/DC unit.

6.

Remove the manifold. See Replacing the ejector (PCE103).

7.

Remove the three bolts from the bottom of the main bracket. See Figure 158.

Figure 158. Remove bottom bolts 8.

Remove the two bolts from the top of the main bracket. Remove bracket. See Figure 159.

Figure 159. Remove top bolts 9.

Remove all tubing connected to components attached to the humidifier. See Figure 160.

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Figure 160. Remove hoses 10. Remove the four bolts that hold the humidifier in place. See Figure 161.

Figure 162. Remove components 1.

HUMIDIFIER

8.

CAPSCREW

2.

SOLENOID VALVE

9.

O-RING

3.

CATHODE EXIT GASKET

10.

CAPSCREW

4.

CATHODE ENTRANCE GASKET

11.

EXHAUST ADAPTER

12.

O-RING

5.

SENSOR

13.

INLET PIPE

6.

CAPSCREW

7.

BYPASS VALVE

12. Remove all the O-rings on the top of the condenser. See Figure 163.

Figure 161. Replacing humidifier 11. Remove all components from the humidifier.

See Figure 162.

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6.

Install manifold. See Replacing the ejector (PCE103).

7.

Install DC/DC unit. See Replacing the DC/DC unit.

8.

Install fuel cell stack. See Replacing the fuel cell stack.

9.

Install the radiator back on to the engine sled.

See Removing and installing the radiator.

10. Install the engine sled back into the fuel cell system. See Removing and installing the engine sled.

11. Perform anode loop leak check. See Leak check anode loop.

12. Re-install the main cover. See Removing and installing the main cover.

Figure 163. Condenser O-rings

13. Recharge the ultracapacitors. See Discharging and recharging the ultracapacitors.

Install NOTE: Before installing new O-rings, coat all Orings with Krytox lubricant. Do not use Krytox lubricant on gaskets (items 3 and 4).

1.

Install new O-rings on top of condenser. See Figure 163.

2.

Locate the components removed in Step 11.

See Figure 162.

• Install solenoid valve, (item 2).

• Install Inlet pipe, (item 13). Torque screws to 8 N•m (5.9 lbf ft.).

• Install exhaust adapter, (item 11). Torque screws to 8 N•m (5.9 lbf ft.).

• Install Bypass valve, (item 7). Torque screws to 12 N•m (8.9 lbf ft.).

3.

Attach the new humidifier to the condenser.

Insert the four bolts and torque to 35 N•m (25.8 lbf ft.). See Figure 161.

4.

Attach hoses to all components. See Figure 160.

5.

Install bolts back into bracket and reattach bracket. See Figure 158 and Figure 159.

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Service procedures

Replacing thermocouples (TT304 and TT351)

NOTE: This list does not include tools required for additional service procedures. Check the procedures below for necessary tools.

Scope

Remove

To remove and replace the thermocouples (TT304 and TT351).

1.

Confirm ultracapacitors are discharged. See Discharging and recharging the ultracapacitors.

2.

Vent hydrogen from the fuel system. See Vent hydrogen from engine plumbing lines.

3.

Remove the main cover from the fuel cell system. See Removing and installing the main cover.

4.

Drain coolant. See Draining and filling coolant.

5.

Remove fuel cell stack. See Replacing the fuel cell stack.

6.

Locate TT304 and TT351. See Figure 164.

Safety and warnings NOTE: Do not perform this procedure unless you have fully read and understand this document.

1.

Read this manual and other specified documentation in their entirety before servicing this equipment.

2.

Before performing this procedure, ensure that you have the proper skill and specialty training needed to perform this procedure as it applies to both the Nuvera® Fuel Cell System and all supplemental equipment used. If you feel that you are not qualified to perform this procedure, contact Nuvera Fuel Cells LLC.

3.

Use caution when handling all parts in the fuel cell, as they may contain compressed hydrogen gas.

DANGER Hydrogen gas is flammable. Eliminate all ignition sources. Do not place an ignition source within 25 feet of this unit. DO NOT SMOKE WITHIN A 25 FOOT RADIUS OF THE FUEL CELL.

Figure 164. Replace thermocouples 1.

PS104

3.

TT304

2.

TT351

4.

PT157

7.

To remove TT351, see Figure 164 and perform the following steps:

Parts and materials required Nuvera part number

Description

N/A

Replacement thermocouple

Qty. 2

120

a.

Unthread and remove PS104.

b.

Disconnect the wire harness from TT351.

c.

Unthread and remove TT351 from the manifold. www.nuvera.com

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Service procedures

8.

To remove TT304, see Figure 164 and perform the following steps: a.

Disconnect the wire harness from TT304.

b.

Unthread and remove TT304 from the manifold.

1.

Apply a small amount of Krytox® lubricant to the O-rings of the thermocouple sensors before installing.

2.

To install TT351, see Figure 164 and perform the following steps:

Install If your fuel cell system is equipped with the old style thermocouple, it must be replaced with the new style.

Figure 165. GEMS integrated sensor (old)

3.

a.

Thread the new thermocouple (TT351) into the manifold.

b.

Connect the wire harness to TT351.

c.

Thread PS104 back into the manifold.

To install TT304, see Figure 164 and perform the following steps: a.

Thread the new thermocouple (TT304) into the manifold.

b.

Connect the wire harness to TT304.

4.

Install fuel cell stack.

SeeReplacing the fuel cell stack .

5.

Refill coolant. See Draining and filling coolant.

6.

Perform coolant leak check. See Leak check coolant loop.

7.

Install main cover on fuel cell system. See Removing and installing the main cover.

8.

Perform anode loop leak check. See Leak check anode loop.

9.

Recharge the ultracapacitors. See Discharging and recharging the ultracapacitors.

10. Update the NFCST software for new thermocouples.

Replacing pressure switch (PS104) or pressure transducer (PT157)

Scope

Figure 166. US flying leads sensor (new)

To remove and replace pressure switch (PS104) or pressure transducer (PT157).

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Safety and warnings

2.

Vent hydrogen from the fuel system. See Vent hydrogen from engine plumbing lines.

NOTE: Do not perform this procedure unless you have fully read and understand this document.

3.

Remove the main cover from the fuel cell system. See Removing and installing the main cover.

4.

Drain coolant. See Draining and filling coolant.

5.

Remove fuel cell stack. See Replacing the fuel cell stack.

6.

Locate PS104 and PT157. See Figure 167.

1.

2.

3.

Read this manual and other specified documentation in their entirety before servicing this equipment.

Before performing this procedure, ensure that you have the proper skill and specialty training needed to perform this procedure as it applies to both the Nuvera® Fuel Cell System and all supplemental equipment used. If you feel that you are not qualified to perform this procedure, contact Nuvera Fuel Cells LLC. Use caution when handling all parts in the fuel cell, as they may contain compressed hydrogen gas.

DANGER Hydrogen gas is flammable. Eliminate all ignition sources. Do not place an ignition source within 25 feet of this unit. DO NOT SMOKE WITHIN A 25 FOOT RADIUS OF THE FUEL CELL.

Figure 167. Replace PS104 or PT157

Parts and materials required

1.

PS104

3.

TT304

2.

TT351

4.

PT157

7.

To remove PS104, see Figure 167 and perform the following steps:

Nuvera part number

Description

Qty.

a.

Disconnect the wire harness from PS104.

N/A

PS104

1

b.

N/A

PT157

1

Unthread and remove PS104 from the manifold

NOTE: This list does not include tools required for additional service procedures. Check the procedures below for necessary tools.

8.

Remove 1.

Confirm ultracapacitors are discharged. See Discharging and recharging the ultracapacitors.

122

To remove PT157, see Figure 167 and perform the following steps: a.

Disconnect the wire harness from PT157.

b.

Unthread and remove PT157 from the manifold.

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Nuvera® Fuel Cell System C95A-33 Service Manual

Service procedures

Install 1.

Apply a small amount of Krytox® lubricant to the O-rings of the pressure switch or pressure transducer before installing.

2.

To install PS104, see Figure 167 and perform the following steps:

3.

a.

Thread the new pressure sensor (PS104) into the manifold.

b.

Connect the wire harness to PS104.

To install PT157, see Figure 167 and perform the following steps: a.

Thread the new pressure transducer (PT157) into the manifold.

b.

Connect the wire harness to PT157.

4.

Install fuel cell stack. See Replacing the fuel cell stack.

5.

Refill coolant. See Draining and filling coolant.

6.

Perform coolant leak check.

SeeLeak check coolant loop.

7.

Install main cover on fuel cell system. See Removing and installing the main cover.

8.

Perform anode loop leak check. See Leak check anode loop.

9.

Recharge the ultracapacitors. See Discharging and recharging the ultracapacitors.

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Tools required

Replacing fuses (F02, F05, F06)

Scope To remove and replace the fuses.

Safety and warnings NOTE: Do not perform this procedure unless you have fully read and understand this document.

1.

Read this manual and other specified documentation in their entirety before servicing this equipment.

2.

Before performing this procedure, ensure that you have the proper skill and specialty training needed to perform this procedure as it applies to both the Nuvera® Fuel Cell System and all supplemental equipment used. If you feel that you are not qualified to perform this procedure, contact Nuvera Fuel Cells LLC.

3.

Use caution when handling all parts in the fuel cell, as they may contain compressed hydrogen gas.

Nuvera part number

Description

Qty.

N/A

Hex head keys

1 set

N/A

Fuse puller

1

NOTE: This list does not include tools required for additional service procedures. Check the procedures below for necessary tools.

Remove fuses from the fuse box 1.

Remove the access panel on the main cover.

See Figure 168.

DANGER Hydrogen gas is flammable. Eliminate all ignition sources. Do not place an ignition source within 25 feet of this unit. DO NOT SMOKE WITHIN A 25 FOOT RADIUS OF THE FUEL CELL.

CAUTION For continued protection against risk of equipment damage and fire, replace only with fuses of the same type and having the same electrical ratings.

Figure 168. Access panel 2.

Locate the fuse box next to the air inlet assembly.

• For fuel cell systems up to and including S/N A2D1S01500R, see Figure 169.

• For fuel cell systems S/N A2D1S01501R and after, see Figure 170.

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Figure 169. Fuse box, fuel cell systems up to and including S/N A2D1S01500R

Figure 171. Fuses

Install fuses into the fuse box 1.

Insert new fuse into fuse box. See Figure 171.

2.

Close the fuse box cover.

3.

Install the access panel back on to the main cover. See Figure 168.

4.

Install capscrews back onto access panel.

Tighten screws to 19.4 N•m (14.3 lbf ft.).

Figure 170. Fuse box,fuel cell systems S/N A2D1S01501R and after 1.

BOLT

4.

FUSE

2.

WASHER

5.

RELAYS

3.

FUSE BOX BRACKET

6.

FUSE BOX

3.

Open the fuse box cover.

4.

Locate the fuse that needs to be replaced (Figure 171).

5.

Use fuse puller to remove fuse from fuse box.

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Service procedures

Replacing relays (K06 and K14)

Remove relays

Scope

1.

To remove and replace the relays.

Safety and warnings NOTE: Do not perform this procedure unless you have fully read and understand this document.

1.

Read this manual and other specified documentation in their entirety before servicing this equipment.

2.

Before performing this procedure, ensure that you have the proper skill and specialty training needed to perform this procedure as it applies to both the Nuvera® Fuel Cell System and all supplemental equipment used. If you feel that you are not qualified to perform this procedure, contact Nuvera Fuel Cells LLC.

3.

Use caution when handling all parts in the fuel cell, as they may contain compressed hydrogen gas.

Confirm ultracapacitors are discharged. See Discharging and recharging the ultracapacitors.

NOTE: Follow the procedures in Step 2. through Step 4. for fuel cell systems up to and including S/N A2D1S01500R. For fuel cell systems S/N A2D1S01501R and after, see Step 5. through Step 7.

2.

Remove the main cover. See Removing and installing the main cover.

3.

Locate the two relays on the main bracket, near the radiator. See Figure 172.

DANGER Hydrogen gas is flammable. Eliminate all ignition sources. Do not place an ignition source within 25 feet of this unit. DO NOT SMOKE WITHIN A 25 FOOT RADIUS OF THE FUEL CELL.

Figure 172. Relays, fuel cell systems up to and including S/N A2D1S01500R

Tools required Nuvera part number

Description

Qty.

N/A

Hex head keys

1 set

1.

K14

2.

4.

Lift relay up to remove.

K6

NOTE: Perform the following procedures for fuel cell systems S/N A2D1S01501R and after.

5.

Remove the access panel on the main cover.

See Figure 173.

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NOTE: This list does not include tools required for additional service procedures. Check the procedures below for necessary tools.

Nuvera® Fuel Cell System C95A-33 Service Manual

Service procedures

Figure 174. Relays, fuel cell systems S/N A2D1S01501R and after 1.

BOLT

4.

FUSES

2.

WASHER

5.

RELAYS (K06, CR14)

3.

FUSE BOX BRACKET

6.

FUSE BOX

7.

Lift relay up to remove.

Figure 173. Access panel 1.

CAPSCREW

3.

MAIN COVER

2.

ACCESS PANEL

6.

Locate the two relays on the fuse box bracket. See Figure 174.

Install relays 1.

Insert new relay.

• For fuel cell systems up to and including S/N A2D1S01500R, see Figure 172.

• For fuel cell systems S/N A2D1S01501R and after, see Figure 174.

2.

Install the cover.

• For fuel cell systems up to and including S/N A2D1S01500R, see Step 2.

• For fuel cell systems S/N A2D1S01501R and after, see Step 5.

3.

127

Recharge the ultracapacitors. See Discharging and recharging the ultracapacitors.

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Service procedures

Parts and materials required

Replacing and recharging the 24 Volt battery system

Scope To replace or recharge the two 12 Volt batteries.

Safety and warnings NOTE: Do not perform this procedure unless you have fully read and understand this document.

1.

Read this manual and other specified documentation in their entirety before servicing this equipment.

2.

Before performing this procedure, ensure that you have the proper skill and specialty training needed to perform this procedure as it applies to both the Nuvera® Fuel Cell System and all supplemental equipment used. If you feel that you are not qualified to perform this procedure, contact Nuvera Fuel Cells LLC.

3.

Use caution when handling all parts in the fuel cell, as they may contain compressed hydrogen gas.

Nuvera part number

Description

Qty.

N/A

External power supply

1

31001384

24v Lithium ion battery

2

Recharge 1.

Confirm ultracapacitors are discharged. See Discharging and recharging the ultracapacitors.

2.

Remove the main cover from the fuel cell system. See Removing and installing the main cover.

3.

Locate the two 12 volt batteries.

4.

Locate the positive and negative battery lead for each battery.

5.

Disconnect the battery leads. See Figure 175.

DANGER Hydrogen gas is flammable. Eliminate all ignition sources. Do not place an ignition source within 25 feet of this unit. DO NOT SMOKE WITHIN A 25 FOOT RADIUS OF THE FUEL CELL.

Tools required Nuvera part number

Description

Qty.

N/A

Hex head keys

1 set

Figure 175. Battery terminals

NOTE: This list does not include tools required for additional service procedures. Check the procedures below for necessary tools.

6.

Ensure power supply voltage is at desired SP prior to connecting terminals.

7.

Connect terminals to external power supply.

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• If charging batteries individually, charge each to 13.7 volts. www.nuvera.com

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Service procedures

• If charging both, charge the series to 27.5 volts.

8.

Connect the positive and negative leads back to each battery. There should be a direct jumper connection between one battery's positive and the other batteries negative terminal.

9.

Install the main cover to the fuel cell system.

See Removing and installing the main cover.

10. Recharge the ultracapacitors. See Discharging and recharging the ultracapacitors.

Figure 177. Batteries, fuel cell systems S/N A2D1S01501R and after

Remove 1.

Disconnect the battery leads.

• For fuel cell systems up to and including S/N A2D1S01500R, see Figure 176.

• For fuel cell systems S/N A2D1S01501R and after, see Figure 177.

1.

LEADS

5.

WASHER

2.

BATTERIES

6.

MAIN WIRE HARNESS

3.

BRACKET

7.

BATTERY JUMPER

4.

BOLT

2.

Use the 2.5 mm hex head key to remove the two screws on the battery hold down strap.

Remove the hold down strap.

3.

Remove batteries.

Install 1.

Locate new batteries. See Storing the Lithium-ion batteries to confirm each battery is within the 12 month time interval or state of charge is 95-100%.

• Battery is within the 12 month time interval.

• State of charge is 95-100%.

Figure 176. Batteries, fuel cell systems up to and including S/N A2D1S01500R

2.

Install batteries on to battery tray.

1.

LEADS

3.

BRACKET

3.

2.

BATTERIES

4.

CAPSCREWS

Place the battery hold down strap on top of the batteries.

• For fuel cell systems up to and including S/N A2D1S01500R, see Figure 176.

• For fuel cell systems S/N A2D1S01501R and after, see Figure 177.

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4.

Insert the two screws to secure the battery hold down strap.

5.

Use the 2.5 mm hex head key to tighten the screws. Torque to 21-25 N•m (15.5-18.4 lbf ft.).

6.

Connect the positive and negative leads back to each battery.

7.

Install the main cover to the fuel cell system.

See Removing and installing the main cover.

8.

Recharge the ultracapacitors. See Discharging and recharging the ultracapacitors.

Figure 178. Battery label • If the battery has been sitting for more than 12 months, it must be recharged.

• Determine the current battery state of charge.

Storing the Lithium-ion batteries • Long term storage is defined as any battery that has not been used for 30 days.

• Any battery in the field that will knowingly not be used for 30 days or more, must be disconnected.

• The lithium-ion batteries have a storage shelf-life of 12 months from date of manufacturing. The manufacture date can be determined from the battery label.

• Locate the serial number below the barcode. See Figure 178.

• Find the four-digit portion of the serial number as indicated in Figure 178.

• The first two digits refer to the week of manufacture. The second two digits refer to the year of manufacture. In the example in Figure 178, the four digit number is 1616. This indicates the battery was manufactured in the 16th week of 2016.

130

• Use a multimeter tool to test battery voltage.

• Divide that measurement by 4 and then consult the chart below to find the depth of discharge (DoD). See Figure 179.

• Subtract the depth of discharge reading from 100 to find approximate state of charge (example, if DoD reading is 66%, the SoC approximately 34%).

• The battery must also be recharged any time the SoC is tested and reading is below 35%.

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Nuvera® Fuel Cell System C95A-33 Service Manual

Service procedures

Figure 179. Depth of discharge vs. battery cell voltage 131

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Nuvera® Fuel Cell System C95A-33 Service Manual

Service procedures

Replacing drain valve (XV154) and purge valve (XV155)

NOTE: This list does not include tools required for additional service procedures. Check the procedures below for necessary tools.

Scope

Remove

To remove and replace the solenoid valves (XV154 and XV155).

Safety and warnings NOTE: Do not perform this procedure unless you have fully read and understand this document.

1.

Read this manual and other specified documentation in their entirety before servicing this equipment.

2.

Before performing this procedure, ensure that you have the proper skill and specialty training needed to perform this procedure as it applies to both the Nuvera® Fuel Cell System and all supplemental equipment used. If you feel that you are not qualified to perform this procedure, contact Nuvera Fuel Cells LLC.

3.

NOTE: All hydrogen must be vented from engine plumbing before servicing. See Vent hydrogen from engine plumbing lines.

1.

Confirm ultracapacitors are discharged. See Discharging and recharging the ultracapacitors.

2.

Remove the main cover. See Removing and installing the main cover.

3.

Locate the solenoid valve(s), connected to the side of the humidifier on the fuel cell stack.

NOTE: The fuel cell stack may need to be removed in order to access the solenoid valve(s).

See Replacing the fuel cell stack.

• For fuel cell systems up to and including S/N A2D1S01500R, see Figure 180.

• For fuel cell systems S/N A2D1S01501R and after, see Figure 181.

Use caution when handling all parts in the fuel cell, as they may contain compressed hydrogen gas.

DANGER Hydrogen gas is flammable. Eliminate all ignition sources. Do not place an ignition source within 25 feet of this unit. DO NOT SMOKE WITHIN A 25 FOOT RADIUS OF THE FUEL CELL.

Tools required Nuvera part number

Description

Qty.

N/A

Hex head keys

1 set

N/A

Flat head screwdriver

1

132

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Nuvera® Fuel Cell System C95A-33 Service Manual

Service procedures

5.

Place a flat head screwdriver at the end of the center shaft and turn counterclockwise until the valve is loose.

Install

Figure 180. XV154 and XV155, fuel cell systems up to and including S/N A2D1S01500R 1.

XV155

2.

XV154

3.

1.

Attach the solenoid portion to the valve body.

2.

Install the nut securing the solenoid onto the center shaft of the valve.

3.

Install the valve to the side of the humidifier.

• For fuel cell systems up to and including S/N A2D1S01500R, see Figure 180.

• For fuel cell systems S/N A2D1S01501R and after, see Figure 181.

4.

Place a flat head screwdriver at the end of the center shaft and turn clockwise until the valve is tight.

5.

If the fuel cell stack was removed, install the fuel cell stack back into the engine sled. See Replacing the fuel cell stack.

6.

Install the main cover. See Removing and installing the main cover.

7.

Perform anode loop leak check. See Leak check anode loop.

8.

Recharge the ultracapacitors. See Discharging and recharging the ultracapacitors.

MANIFOLD

Figure 181. XV155, fuel cell systems S/N A2D1S01501R and after 1.

XV155

2.

MANIFOLD

4.

Loosen and remove the nut securing the solenoid onto the center shaft. Remove the solenoid portion from the valve body.

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Service procedures

Replacing the ejector (PCE103)

NOTE: This tool list does not include tools needed for additional procedures that may be needed for this service. Check the procedures listed below for all tools needed.

Scope To remove the ejector and replace with new.

Parts and materials required

Safety and warnings NOTE: Do not perform this procedure unless you have fully read and understand this document.

1.

Read this manual and other specified documentation in their entirety before servicing this equipment.

2.

Before performing this procedure, ensure that you have the proper skill and specialty training needed to perform this procedure as it applies to both the Nuvera® Fuel Cell System and all supplemental equipment used. If you feel that you are not qualified to perform this procedure, contact Nuvera Fuel Cells LLC.

3.

Use caution when handling all parts in the fuel cell, as they may contain compressed hydrogen gas.

DANGER Hydrogen gas is flammable. Eliminate all ignition sources. Do not place an ignition source within 25 feet of this unit. DO NOT SMOKE WITHIN A 25 FOOT RADIUS OF THE FUEL CELL.

Tools required Nuvera part number

Description

Qty.

N/A

11/16" wrench

1

N/A

4 mm Hex head wrench

1

N/A

6 mm Hex head wrench

1

Nuvera part number

Description

Qty.

300000400

Gasket

1

300000401

Gasket

1

Prepare The fuel cell stack must be removed before replacing the ejector. Before removing the fuel cell stack, the following procedures must be performed: 1.

Vent hydrogen from engine plumbing lines

2.

Discharging and recharging the ultracapacitors

Remove 1.

Remove the main cover from the fuel cell system. See Removing and installing the main cover.

2.

Drain the coolant from the stack. See Draining and filling coolant.

3.

Remove the fuel cell stack. See Replacing the fuel cell stack.

4.

Use a 11/16" wrench to remove the Swagelok™ nut from the ejector. Remove the fuel line tube from the ejector fitting.

• For fuel cell systems up to and including S/N A2D1S01500R, see Figure 182.

• For fuel cell systems S/N A2D1S01501R and after, see Figure 183.

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Figure 182. Removing fuel line from ejector fitting, fuel cell systems up to and including S/N A2D1S01500R 1.

FUEL LINE

5.

TT351

Figure 183. Removing fuel line from ejector fitting, fuel cell systems S/N A2D1S01501R and after

2.

EJECTOR FITTING

6.

TT304

1.

FUEL LINE

5.

TT351

3.

NUT

7.

PT157

2.

EJECTOR FITTING

6.

TT304

4.

PS104

3.

NUT

7.

PT157

4.

PS104

5.

Disconnect all four sensor connectors (PS104, TT351, TT304, and PT157) from the manifold.

6.

Remove front and rear insulation by gently pulling it away from the manifold.

• For fuel cell systems up to and including S/N A2D1S01500R, see Figure 184.

• For fuel cell systems S/N A2D1S01501R and after, see Figure 185.

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Figure 184. Insulation, fuel cell systems up to and including S/N A2D1S01500R

Figure 186. Removing manifold, fuel cell systems up to and including S/N A2D1S01500R

Figure 185. Insulation, fuel cell systems S/N A2D1S01501R and after

Figure 187. Removing manifold, fuel cell systems S/N A2D1S01501R and after

Use a 6 mm hex head key to remove the six bolts connecting the manifold to the engine.

8.

Lift the manifold out of the unit and place it on a work bench.

• For fuel cell systems up to and including S/N A2D1S01500R, see Figure 186.

• For fuel cell systems S/N A2D1S01501R and after, see Figure 187.

9.

Use a 4 mm hex head key to remove the four bolts on the flange, attaching the ejector to the manifold. Gently pull the ejector out of the manifold.

7.

• For fuel cell systems up to and including S/N A2D1S01500R, see Figure 188.

• For fuel cell systems S/N A2D1S01501R and after , see Figure 189.

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Figure 188. Removing the ejector, fuel cell systems up to and including S/N A2D1S01500R

Figure 190. Removing hardware from ejector 1.

EJECTOR

4.

SPACER

2.

O-RING

5.

FLANGE

3.

WASHER

6.

FITTING

Install 1.

Install the O-ring, washer, and spacer as removed in the previous step, onto the new ejector by sliding over the fitting. See Figure 190.

2.

Squeeze out a small amount of Krytox™ on a fingertip and apply a thin coat to the O-rings.

See Figure 191.

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Figure 189. Removing the ejector, fuel cell systems S/N A2D1S01501R and after 10. Slide the O-ring, washer, and spacer over the fitting and remove from ejector. See Figure 190.

Nuvera® Fuel Cell System C95A-33 Service Manual

Service procedures

Figure 191. Apply grease to ejector hardware 3.

4.

5.

Insert the new ejector assembly into the manifold, confirming the fitting is pointing directly up.

Place the flange over the ejector. Use the 4 mm hex head key to install the 4 bolts securing the flange to the manifold.

7.

With the torque wrench set at 35 N•m, retighten the bolts in numerical order as shown in Figure 192.

• For fuel cell systems up to and including S/N A2D1S01500R, see Figure 188.

• For fuel cell systems S/N A2D1S01501R and after , see Figure 189.

8.

Connect the four sensors to the manifold.

Use new gaskets (no lube) and place the manifold back onto the engine. Install the six mounting bolts to finger-tight.

• For fuel cell systems up to and including S/N A2D1S01500R, see Figure 186.

• For fuel cell systems S/N A2D1S01501R and after , see Figure 187.

NOTE: Torquing the bolts on the manifold is a two-step process. Make sure both Step 6. and Step 7. are performed.

6.

Figure 192. Bolt torque pattern

Use a torque wrench set at 17 N•m and tighten the bolts in the numerical order as shown in Figure 192. Set the torque wrench to 35 N•m.

• For fuel cell systems up to and including S/N A2D1S01500R, see Figure 182.

• For fuel cell systems S/N A2D1S01501R and after, see Figure 183.

9.

Connect the fuel line to the ejector fitting.

10. Apply a light coating of spray adhesive to the insulation pieces and place insulation back on to the manifold.

• For fuel cell systems up to and including S/N A2D1S01500R, see Figure 184.

• For fuel cell systems S/N A2D1S01501R and after , see Figure 185.

11. Install the fuel cell stack. See Replacing the fuel cell stack.

12. Add coolant back into the stack. See Draining and filling coolant.

13. Re-install the main cover. See Removing and installing the main cover.

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14. Perform anode loop leak check. See Leak check anode loop.

15. Recharge the ultracapacitors. See Discharging and recharging the ultracapacitors.

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Replacing the ultracapacitor module

Scope To remove and replace the ultracapacitor module.

Nuvera part number

Description

Qty.

N/A

CAN-to-USB adapter (Leaflight v2.0)

1

N/A

HYG standard diagnostic cable (3-pin Deutsch to DB9)

1

N/A

Socket set

1 set

N/A

Socket wrench

1

N/A

Hex head keys

1 set

N/A

D-clamps

1

N/A

Tow straps

1

Safety and warnings NOTE: Do not perform this procedure unless you have fully read and understand this document.

1.

2.

3.

Read this manual and other specified documentation in their entirety before servicing this equipment.

Before performing this procedure, ensure that you have the proper skill and specialty training needed to perform this procedure as it applies to both the Nuvera® Fuel Cell System and all supplemental equipment used. If you feel that you are not qualified to perform this procedure, contact Nuvera Fuel Cells LLC. Use caution when handling all parts in the fuel cell, as they may contain compressed hydrogen gas.

NOTE: This list does not include tools required for additional service procedures. Check the procedures below for necessary tools.

Parts and material required

DANGER Hydrogen gas is flammable. Eliminate all ignition sources. Do not place an ignition source within 25 feet of this unit. DO NOT SMOKE WITHIN A 25 FOOT RADIUS OF THE FUEL CELL.

Tools required Nuvera part number

Description

Qty.

N/A

Load bank

1

N/A

Laptop w/ Nuvera FCS Service Tool Installed

1

Nuvera part number

Description

Qty.

N/A

Class I Ultracapacitors

1 set

Prepare 1.

Confirm ultracapacitors are discharged. See Discharging and recharging the ultracapacitors.

2.

Remove the main cover. See Removing and installing the main cover.

3.

Vent hydrogen from fuel system. See Vent hydrogen from engine plumbing lines.

4.

Remove the engine sled from the fuel cell system. See Removing and installing the engine sled.

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Remove 1.

Disconnect the negative Anderson cable.

2.

Loosen and remove the nuts attaching the Positive and Negative ultracapacitor buss bars to the buss bar brackets.

• For fuel cell systems up to and including S/N A2D1S01500R, see Figure 193.

• For fuel cell systems S/N A2D1S01501R and after, see Figure 194.

Figure 194. Buss bars, fuel cell systems S/N A2D1S01501R and after 1.

FLAT HEAD BOLT

4.

POSITIVE BUSS BAR

2.

NUT

5.

NEGATIVE BUSS BAR

3.

BOLT

3.

Use a 6 mm hex key to remove the two bolts from the bottom of the DC/DC back wall.

• For fuel cell systems up to and including S/N A2D1S01500R, see Figure 195.

• For fuel cell systems S/N A2D1S01501R and after, see Figure 196.

Figure 193. Buss bars, fuel cell systems up to and including S/N A2D1S01500R 1.

FLAT HEAD BOLT

4.

POSITIVE BUSS BAR

2.

NUT

5.

NEGATIVE BUSS BAR

3.

BOLT

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Figure 195. DC/DC bracket, fuel cell systems up to and including S/N A2D1S01500R 1.

BOTTOM BOLTS

2.

TOP BOLT

3.

DC/DC BRACKET

Figure 196. DC/DC bracket, fuel cell systems S/N A2D1S01501R and after 1.

BOTTOM BOLTS

3.

DC/DC BRACKET

2.

TOP BOLT

4.

Use 6 mm hex key to remove the bolt from the top of the DC/DC bracket.

5.

Gently remove the DC/DC bracket from the rear of the fuel cell system, to allow access to the three rear bolts on the ultracapacitor module assembly.

• For fuel cell systems up to and including S/N A2D1S01500R, see Figure 197.

• For fuel cell systems S/N A2D1S01501R and after, see Figure 198.

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Figure 197. Ultracapacitor module, fuel cell systems up to and including S/N A2D1S01500R 1.

FRONT BOLTS

2.

REAR BOLTS

3.

ULTRACAPACITOR MODULE

Figure 198. Ultracapacitor module, fuel cell systems S/N A2D1S01501R and after 1.

FRONT BOLTS

2.

REAR BOLTS

6.

Use a 4 mm hex key to remove the rear bolts.

7.

Lift the ultracapacitor module out of the engine sled.

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ULTRACAPACITOR MODULE

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Install 1.

Lower the new ultracapacitor module into the engine sled.

2.

Install the three rear bolts. Use the 4 mm hex key to tighten.

• For fuel cell systems up to and including S/N A2D1S01500R, see Figure 197.

• For fuel cell systems S/N A2D1S01501R and after, see Figure 198.

3.

Install the three front bolts. Use the 4 mm hex key to tighten.

4.

Install the DC/DC bracket and insert the two bolts to attach the bottom of the bracket to the engine sled.

• For fuel cell systems up to and including S/N A2D1S01500R, see Figure 195.

• For fuel cell systems S/N A2D1S01501R and after, see Figure 196.

5.

Install the positive and negative ultracapacitor buss bar.

• For fuel cell systems up to and including S/N A2D1S01500R, see Figure 193.

• For fuel cell systems S/N A2D1S01501R and after, see Figure 194.

6.

Connect the negative Anderson cable.

7.

Install the engine sled back into the fuel cell system. See Removing and installing the engine sled.

8.

Re-install the main cover. See Removing and installing the main cover.

9.

Perform anode loop leak check. See Leak check anode loop.

10. Recharge the ultracapacitors. See Discharging and recharging the ultracapacitors.

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Replacing the DC/DC unit

NOTE: This tool list does not include tools needed for additional procedures that may be needed for this service. Check the procedures listed below for all tools needed.

Scope To remove and install the DC/DC unit.

Remove

Safety and warnings

1.

Confirm the ultracapacitors are discharged.

See Discharging and recharging the ultracapacitors.

2.

Remove the main cover from the fuel cell system. See Removing and installing the main cover.

3.

Vent hydrogen fuel system. See Vent hydrogen from engine plumbing lines.

4.

Remove the engine sled from the fuel cell system. See Removing and installing the engine sled.

5.

Remove the POS lead from the 24V battery system. See Figure 199.

NOTE: Do not perform this procedure unless you have fully read and understand this document.

1.

Read this manual and other specified documentation in their entirety before servicing this equipment.

2.

Before performing this procedure, ensure that you have the proper skill and specialty training needed to perform this procedure as it applies to both the Nuvera® Fuel Cell System and all supplemental equipment used. If you feel that you are not qualified to perform this procedure, contact Nuvera Fuel Cells LLC.

3.

Use caution when handling all parts in the fuel cell, as they may contain compressed hydrogen gas.

DANGER Hydrogen gas is flammable. Eliminate all ignition sources. Do not place an ignition source within 25 feet of this unit. DO NOT SMOKE WITHIN A 25 FOOT RADIUS OF THE FUEL CELL.

Tools required Nuvera part number

Description

Qty.

N/A

10 mm, 13 mm wrenches

1 ea.

N/A

6 mm hex key

1

Figure 199. Battery leads 6.

Remove the bolt from the top rear mounting bracket (item 3).

• For fuel cell systems up to and including S/N A2D1S01500R, see Figure 200.

• For fuel cell systems S/N A2D1S01501R and after, see Figure 201.

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7.

Remove the two bolts holding the DC/DC to the engine base plate.

• For fuel cell systems up to and including S/N A2D1S01500R, see Figure 202.

• For fuel cell systems S/N A2D1S01501R and after, see Figure 203.

Figure 200. Top rear mounting bolt, fuel cell systems up to and including S/N A2D1S01500R 1.

FLAT HEAD BOLT

2.

NUT

3.

BOLT

4.

POS. ULTRACAPS BUSS BAR

5.

NEG. ULTRACAPS BUSS BAR

Figure 202. DC/DC bracket, fuel cell systems up to and including S/N A2D1S01500R 1.

BOTTOM BOLTS

2.

TOP BOLT

3.

DC/DC BRACKET

Figure 201. Top rear mounting bolt, fuel cell systems S/N A2D1S01501R and after 1.

FLAT HEAD BOLT

2.

NUT

3.

BOLT

4.

POS. ULTRACAPS BUSS BAR

5.

NEG. ULTRACAPS BUSS BAR

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Figure 204. DC/DC unit

Figure 203. DC/DC bracket, fuel cell systems S/N A2D1S01501R and after

TIE WRAPS

5.

LOWER POS. BUSS BAR

2.

UPPER POS. BUSS BAR

6.

LOWER POS. CABLE

3.

CAP POS. WIRE

7.

INDUCTOR LEAD

4.

24V LEAD WIRE

8.

GROUNDING BOLT

10. Use the 13 mm socket wrench to remove the upper Pos. buss bar and CAP Pos. wire from the DC/DC (2, 3, Figure 204).

1.

BOTTOM BOLTS

2.

TOP BOLT

8.

Gently pull the DC/DC clear of the engine, just enough to allow access between the DC/DC and the fuel cell stack.

9.

3.

1.

DC/DC BRACKET

Cut the two tie wraps holding the Pos. buss bars for the CAP and the stack (1, Figure 204).

Pull DC/DC back slightly.

11. Use the 13 mm socket wrench to remove the lower Pos. buss bar from the DC/DC (5, Figure 204).

12. Use the 10 mm wrench to remove the nut from the 24V lead wire on the DC/DC (4, Figure 204).

13. Use the 10 mm wrench to remove the lower Pos. cable from the Motor Controller to the DC/DC (6, Figure 204).

14. Use the 13 mm socket wrench to remove the inductor lead from the DC/DC (7, Figure 204).

15. Use the 13 mm socket wrench to remove the ground bolt and the four leads from the front of the DC/DC (8, Figure 204).

16. Disconnect the sub harness connector from the main harness.

17. Remove the DC/DC unit from the engine.

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Install 1.

Place the removed DC/DC unit on a work bench next to the new DC/DC unit.

2.

Disconnect the wire harness from the removed DC/DC unit and connect it to the new DC/DC unit.

3.

Place the new DC/DC unit with wire harness in position in the fuel cell system. Leave sufficient room between the unit and the stack to attach components.

4.

Connect the DC/DC wire harness connector to the main fuel cell system wire harness.

5.

Use the 13 mm socket wrench to install the ground bolt and the four leads to the front of the DC/DC (8, Figure 204).

6.

Use the 13 mm socket wrench to install the inductor lead to the DC/DC (7, Figure 204).

7.

Use the 10 mm wrench to attach the lower Pos. cable from the MC to the DC/DC (6, Figure 204).

8.

Use the 10 mm wrench to install the nut to the 24V lead wire on the DC/DC (4, Figure 204).

9.

Use the 13 mm socket wrench to attach the lower Pos. buss bar to the DC/DC (5, Figure 204).

13. Use the 6 mm hex key to install the bolt to the top rear mounting bracket.

• For fuel cell systems up to and including S/N A2D1S01500R, see Figure 200.

• For fuel cell systems S/N A2D1S01501R and after, see Figure 201.

14. Attach the Pos. lead to the 24V battery system. See Figure 199.

15. Install the engine sled back into fuel cell system. See Removing and installing the engine sled.

16. Re-install the main cover. See Removing and installing the main cover.

17. Perform anode loop leak check. See Leak check anode loop.

18. Recharge the ultracapacitors. See Discharging and recharging the ultracapacitors.

10. Use the 13 mm socket wrench to attach the upper Pos. buss bar and CAP Pos. wire to the DC/DC (2, 3, Figure 204).

11. Apply two tie wraps to hold the Pos. buss bars for the CAP and the stack (1, Figure 204).

12. Use the 6 mm hex key to install the two bolts holding the DC/DC bracket to the engine base plate.

• For fuel cell systems up to and including S/N A2D1S01500R, see Figure 202.

• For fuel cell systems S/N A2D1S01501R and after, see Figure 203.

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Service procedures

Replacing the motor controller

Scope To remove and install the motor controller.

Safety and warnings NOTE: Do not perform this procedure unless you have fully read and understand this document.

1.

Read this manual and other specified documentation in their entirety before servicing this equipment.

2.

Before performing this procedure, ensure that you have the proper skill and specialty training needed to perform this procedure as it applies to both the Nuvera® Fuel Cell System and all supplemental equipment used. If you feel that you are not qualified to perform this procedure, contact Nuvera Fuel Cells LLC.

3.

Use caution when handling all parts in the fuel cell, as they may contain compressed hydrogen gas.

Nuvera part number

Description

Qty.

N/A

11/16", 3/4", 5/8", 10 mm, 13 mm wrenches

1 ea.

N/A

Pliers

1

N/A

Lifting kit

1

NOTE: This tool list does not include tools needed for additional procedures that may be needed for this service. Check the procedures listed below for all tools needed.

Parts and materials required Nuvera part number

Description

Qty.

N/A

Motor controller

1

Prepare Before removing the motor controller, the following procedures must be performed:

DANGER Hydrogen gas is flammable. Eliminate all ignition sources. Do not place an ignition source within 25 feet of this unit. DO NOT SMOKE WITHIN A 25 FOOT RADIUS OF THE FUEL CELL.

1.

Preparing the truck and removing the fuel cell

2.

Discharging and recharging the ultracapacitors

Remove

Tools required Nuvera part number

Description

N/A

4 mm, 5 mm, 6 mm

1.

Remove the main cover. See Removing and installing the main cover.

2.

Vent hydrogen fuel system. See Vent hydrogen from engine plumbing lines.

3.

Remove the engine sled from the fuel cell system. See Removing and installing the engine sled.

4.

Drain coolant from the system. See Draining and filling coolant.

Qty. 1 ea.

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5.

Remove the fuel cell stack. See Replacing the fuel cell stack.

6.

Remove the DC/DC unit from the engine sled.

See Replacing the DC/DC unit.

7.

Locate the motor controller. See Figure 205.

10. Use the 5 mm hex key to remove the four mounting bolts attaching the motor controller to the bracket. See Figure 206.

Figure 206. Motor controller remove/install Figure 205. Motor controller 1.

MOTOR CONTROLLER

2.

B NEG.

3.

W PHASE

4.

V PHASE

5.

B POS.

6.

U PHASE

7.

MAIN HARNESS CONNECTOR

1.

BOLT

2.

MOTOR CONTROLLER

3.

BRACKET

11. Slide the motor controller out of the engine sled and remove.

Install 8.

Loosen the five bolts to remove the battery and wire terminals at the terminal contacts (B Neg., B Pos., U phase, V phase, W phase). See Figure 205.

9.

Disconnect the main wire harness connector.

See Figure 205.

1.

Locate new flashed motor controller and install into engine sled, aligning the holes on the motor controller and the bracket. See Figure 206.

2.

Insert the four mounting bolts and use the 5 mm hex key to tighten.

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3.

Loosen the five bolts on the new motor controller for the battery and wire terminals.

Connect all five electrical connections at the terminal contacts (B Neg., B Pos., U phase, V phase, W phase). See Figure 205.

4.

Connect the main wire harness connector.

See Figure 205.

5.

Install the DC/DC unit back into the engine sled. See Replacing the DC/DC unit.

6.

Install the fuel cell stack. See Replacing the fuel cell stack.

7.

Add coolant back into the fuel cell system.

See Draining and filling coolant.

8.

Install the engine sled back into the fuel cell system. See Removing and installing the engine sled.

9.

Leak check the coolant system See Leak check coolant loop.

10. Re-install the main cover. See Removing and installing the main cover.

11. Perform anode loop leak check. See Leak check anode loop.

12. Recharge the ultracapacitors. See Discharging and recharging the ultracapacitors.

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Service procedures

Replacing the CVM

NOTE: This tool list does not include tools needed for additional procedures that may be needed for this service. Check the procedures listed below for all tools needed.

Scope To remove and install the CVM.

Prepare

Safety and warnings NOTE: Do not perform this procedure unless you have fully read and understand this document.

1.

2.

3.

Read this manual and other specified documentation in their entirety before servicing this equipment.

Before performing this procedure, ensure that you have the proper skill and specialty training needed to perform this procedure as it applies to both the Nuvera® Fuel Cell System and all supplemental equipment used. If you feel that you are not qualified to perform this procedure, contact Nuvera Fuel Cells LLC.

Before removing the CVM, the following procedures must be performed: 1.

Discharging and recharging the ultracapacitors

Remove 1.

Remove the main cover from the fuel cell system. See Removing and installing the main cover.

2.

Use a 13 mm socket wrench to remove the nuts from the positive and negative buss bar to the ultra capacitors and the buss bars. See Figure 207.

Use caution when handling all parts in the fuel cell, as they may contain compressed hydrogen gas.

• For fuel cell systems up to and including S/N A2D1S01500R, see Figure 207.

• For fuel cell systems S/N A2D1S01501R and after, see Figure 208.

DANGER Hydrogen gas is flammable. Eliminate all ignition sources. Do not place an ignition source within 25 feet of this unit. DO NOT SMOKE WITHIN A 25 FOOT RADIUS OF THE FUEL CELL.

Tools required Nuvera part number

Description

Qty.

N/A

13 mm wrench

1

N/A

4 mm, 5 mm, 6 mm hex keys

1

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3.

Use a 6 mm hex head key to remove the buss bar bolt from the rear mounting flange.

4.

Use a 4 mm hex head key to remove the two flat head bolts from the front mounting flange.

5.

Use a 15 mm socket and wrench to remove the two nuts from the buss bar on the positive side of the stack. Remove the buss bar from the stack. See Figure 209.

Figure 207. Buss bars, fuel cell systems up to and including S/N A2D1S01500R 1.

FLAT HEAD BOLT

4.

POSITIVE BUSS BAR

2.

NUT

5.

NEGATIVE BUSS BAR

3.

BOLT

Figure 209. Removing nuts from buss bar

Figure 208. Buss bars, fuel cell systems S/N A2D1S01501R and after 1.

FLAT HEAD BOLT

4.

POSITIVE BUSS BAR

2.

NUT

5.

NEGATIVE BUSS BAR

3.

BOLT

Figure 210. CVM connectors

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6.

7.

8.

Move the buss bar assembly out of the way, to allow access between the ultracapacitor and the stack from above.

Install 1.

Disconnect the four CVM connectors from the CVM. See Figure 210.

Install the new CVM into the unit by placing it on the three mounting studs.

2.

Use the 13 mm socket to remove the three nuts holding the CVM to the panel. See Figure 211.

Use the 13 mm socket to install the three nuts holding the CVM to the panel. See Figure 211.

3.

Connect the four CVM connectors to the CVM. See Figure 210.

4.

Attach the buss bar to positive side of the stack. Use a 15 mm socket and wrench to install the two nuts to the buss bar. See Figure 209.

5.

Install the two flat head bolts to the front mounting flange. Use a 4 mm hex head key to tighten.

• For fuel cell systems up to and including S/N A2D1S01500R, see Figure 207.

• For fuel cell systems S/N A2D1S01501R and after, see Figure 208.

6.

Install the buss bar bolt to the rear mounting flange. Use a 6 mm hex head key to tighten.

7.

Install the nuts to the positive and negative buss bar and the ultra capacitors and the buss bars. Use a 13 mm socket wrench to tighten.

8.

Re-install the main cover. See Removing and installing the main cover.

9.

Recharge the ultracapacitors. See Discharging and recharging the ultracapacitors.

Figure 211. Removing the CVM 1.

CVM

3.

VSM

2.

NUTS

9.

Slowly remove the CVM from the three mounting studs.

10. Gently lift the CVM up and out of the unit.

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Service procedures

Replacing the VSM

NOTE: This tool list does not include tools needed for additional procedures that may be needed for this service. Check the procedures listed below for all tools needed.

Scope To remove and install the VSM.

Prepare

Safety and warnings NOTE: Do not perform this procedure unless you have fully read and understand this document.

1.

2.

3.

Read this manual and other specified documentation in their entirety before servicing this equipment.

Before performing this procedure, ensure that you have the proper skill and specialty training needed to perform this procedure as it applies to both the Nuvera® Fuel Cell System and all supplemental equipment used. If you feel that you are not qualified to perform this procedure, contact Nuvera Fuel Cells LLC.

Before removing the VSM, the following procedures must be performed: 1.

Discharging and recharging the ultracapacitors

Remove 1.

Remove the main cover from the fuel cell system. See Removing and installing the main cover.

2.

Follow the steps to remove the CVM. See Replacing the CVM.

Use caution when handling all parts in the fuel cell, as they may contain compressed hydrogen gas.

DANGER Hydrogen gas is flammable. Eliminate all ignition sources. Do not place an ignition source within 25 feet of this unit. DO NOT SMOKE WITHIN A 25 FOOT RADIUS OF THE FUEL CELL.

Tools required Nuvera part number

Description

Qty.

N/A

13 mm wrench

1

N/A

4 mm, 5 mm, 6mm hex keys

1 ea.

Figure 212. VSM connectors 1.

V1 CONNECTOR

4.

V4 CONNECTOR

2.

V2 CONNECTOR

5.

V5 CONNECTOR

3.

V3 CONNECTOR

3.

Disconnect the five connectors from the VSM. See Figure 212.

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4.

Use the 13 mm socket to remove the three nuts holding the VSM to the panel. See Figure 213.

3.

Follow the steps to install the CVM. See Replacing the CVM.

4.

Re-install the main cover. See Removing and installing the main cover.

5.

Recharge the ultracapacitors. See Discharging and recharging the ultracapacitors.

Figure 213. Removing the VSM 1.

CVM

3.

VSM

2.

NUTS

5.

Slowly remove the VSM from the three mounting studs.

6.

Gently lift the VSM up and out of the unit.

Install 1.

Use the 13 mm socket to install the three nuts holding the VSM to the panel. See Figure 213.

2.

Connect the 5 connectors to the VSM. See Figure 212.

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Service procedures

Replacing the heater relay

Scope To remove the heater relay and replace with new.

Safety and warnings NOTE: Do not perform this procedure unless you have fully read and understand this document.

1.

Read this manual and other specified documentation in their entirety before servicing this equipment.

2.

Before performing this procedure, ensure that you have the proper skill and specialty training needed to perform this procedure as it applies to both the Nuvera® Fuel Cell System and all supplemental equipment used. If you feel that you are not qualified to perform this procedure, contact Nuvera Fuel Cells LLC.

3.

Nuvera part number

Description

Qty.

N/A

1/4" Open end wrench

1

NOTE: This tool list does not include tools needed for additional procedures that may be needed for this service. Check the procedures listed below for all tools needed.

Remove 1.

Remove the main cover from the fuel cell system. See Removing and installing the main cover.

2.

Follow the procedure in Discharging and recharging the ultracapacitors.

3.

Locate the heater relay mounted on the inside of the power electronics bracket, alligned with the two screw holes pictured.

See Figure 214.

Use caution when handling all parts in the fuel cell, as they may contain compressed hydrogen gas.

DANGER Hydrogen gas is flammable. Eliminate all ignition sources. Do not place an ignition source within 25 feet of this unit. DO NOT SMOKE WITHIN A 25 FOOT RADIUS OF THE FUEL CELL.

Tools required Nuvera part number

Description

Qty.

N/A

1/4" Thin wall socket

1

N/A

5/16" Thin wall socket

1

N/A

Drive bit set

1

Figure 214. Heater relay location

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Service procedures

4.

Use a 2 mm drive bit and the 1/4" open end wrench to remove the top bolt from the relay (Item 3, Figure 215).

Install 1.

Place the relay contactors on the new relay as removed in Step 7. and tighten nuts.

2.

With all relay contactors tightened, position the relay back into place on the bracket.

3.

Install the two bolts to attach the top and bottom of the relay to the bracket.

4.

Use the 2 mm drive bit and the 1/4" open end wrench to tighten the top and bottom bolt.

5.

Recharge the ultracapacitors. See Discharging and recharging the ultracapacitors.

6.

Re-install the main cover. See Removing and installing the main cover.

Figure 215. Remove heater relay 1.

5/16" NUTS

3.

BUTTON HEAD BOLTS

2.

1/4" NUTS

4.

RELAY CONTACTORS

5.

With the top bolt now removed, rotate the relay to the side to allow access to the bottom bolt. Repeat the procedure in Step 4. to remove the bottom bolt.

6.

Pull the relay away from the unit to access the relay contactors.

7.

Remove each relay contactor individually, using 1/4" and 5/16" sockets to remove nuts.

See Figure 215.

8.

Remove the relay and replace with new.

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Service procedures

Replacing solenoid valve (XV101)

NOTE: This list does not include tools required for additional service procedures. Check the procedures below for necessary tools.

Scope

Remove

To remove and replace the solenoid valves (XV101).

Safety and warnings NOTE: Do not perform this procedure unless you have fully read and understand this document.

1.

Read this manual and other specified documentation in their entirety before servicing this equipment.

2.

Before performing this procedure, ensure that you have the proper skill and specialty training needed to perform this procedure as it applies to both the Nuvera® Fuel Cell System and all supplemental equipment used. If you feel that you are not qualified to perform this procedure, contact Nuvera Fuel Cells LLC.

3.

Use caution when handling all parts in the fuel cell, as they may contain compressed hydrogen gas.

All hydrogen must be vented from engine plumbing before servicing. See Vent hydrogen from engine plumbing lines.

1.

Locate the high pressure compartment access panel. See Figure 216.

DANGER Hydrogen gas is flammable. Eliminate all ignition sources. Do not place an ignition source within 25 feet of this unit. DO NOT SMOKE WITHIN A 25 FOOT RADIUS OF THE FUEL CELL.

Tools required Nuvera part number

Description

Qty.

N/A

4 mm hex key

1

N/A

Flat head screwdriver

1

N/A

11/16" wrench

1

Figure 216. High pressure compartment panel 1.

CAPSCREW

3.

HIGH PRESSURE COMPARTMENT

2.

ACCESS PANEL

2.

Use the 4 mm hex key to remove the six capscrews securing the access panel to the fuel cell. Remove the access panel.

3.

Locate the solenoid valve (XV101).

• For fuel cell systems up to and including S/N A2D1S01500R, see Figure 217.

• For fuel cell systems S/N A2D1S01501R and after, see Figure 218.

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Service procedures

Figure 217. Fuel system, fuel cell systems up to and including S/N A2D1S01500R 1.

XV191

5.

HV195

2.

HV183

6.

FV194

3.

PT102

7.

XV101

4.

PCV192 AND PCV193

8.

PT189

Figure 218. Fuel system, fuel cell systems S/N A2D1S01501R and after 1.

XV191

5.

HV195

2.

HV183

6.

FV194

3.

PT189

7.

XV101

4.

PCV192 AND PCV193

4.

Disconnect the inlet and outlet fittings from XV101.

5.

Use the 5 mm hex head key and remove the two bolts securing the mounting bracket to the wall in the high pressure compartment.

Remove the bracket with XV101 still attached.

6.

Use the 11/16" wrench to remove XV101 from the bracket.

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Service procedures

Install 1.

Use the 11/16" wrench to attach the new XV101 to the mounting bracket.

2.

Use the two bolts to secure the bracket with XV101 attached, to the wall in the high pressure compartment. Use the 5 mm hex head key and tighten the bolts.

3.

Connect the inlet and outlet fittings to XV101.

• For fuel cell systems up to and including S/N A2D1S01500R, see Figure 217.

• For fuel cell systems S/N A2D1S01501R and after, see Figure 218.

4.

Tighten fittings.

5.

Check all connections for leaks. See Leak check H2 plumbing.

6.

Install the high pressure compartment access panel.

7.

Insert the capscrews to secure access panel to fuel cell. See Figure 216.

8.

Use hex head wrench to tighten capscrews to 19.4 N•m (14.3 lbf ft.).

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Service procedures

Remove

Replacing FL190, PCV192 and PCV193

Scope

All hydrogen must be vented from engine plumbing before servicing. See Vent hydrogen from engine plumbing lines.

To remove and replace filter (FL190) and the solenoid valves (PCV192 and PCV193), as part of the hydrogen regulating assembly.

1.

Locate the high pressure compartment access panel. See Figure 219.

Safety and warnings NOTE: Do not perform this procedure unless you have fully read and understand this document.

1.

Read this manual and other specified documentation in their entirety before servicing this equipment.

2.

Before performing this procedure, ensure that you have the proper skill and specialty training needed to perform this procedure as it applies to both the Nuvera® Fuel Cell System and all supplemental equipment used. If you feel that you are not qualified to perform this procedure, contact Nuvera Fuel Cells LLC.

3.

Use caution when handling all parts in the fuel cell, as they may contain compressed hydrogen gas.

Figure 219. High pressure compartment access panel

DANGER Hydrogen gas is flammable. Eliminate all ignition sources. Do not place an ignition source within 25 feet of this unit. DO NOT SMOKE WITHIN A 25 FOOT RADIUS OF THE FUEL CELL.

Tools required Nuvera part number

Description

Qty.

N/A

Hex head keys

1 set

1.

CAPSCREW

3.

HIGH PRESSURE COMPARTMENT

2.

ACCESS PANEL

2.

Use hex head wrench to remove the six capscrews securing the access panel to the fuel cell. Remove access panel.

3.

Locate the regulator.

• For fuel cell systems up to and including S/N A2D1S01500R, see Figure 220.

• For fuel cell systems S/N A2D1S01501R and after, see Figure 221.

NOTE: This list does not include tools required for additional service procedures. Check the procedures below for necessary tools.

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Service procedures

Figure 220. Remove/install regulator, fuel cell systems up to and including S/N A2D1S01500R 1.

REGULATOR (FL190, PCV192, PCV193)

6.

OR198

2.

REGULATOR RETAINER

7.

FV194

8.

HV195

3.

WASHER

9.

4.

STAR WASHER

10.

5.

CAPSCREW

Figure 221. Remove/install regulator, fuel cell systems S/N A2D1S01501R and after 1.

REGULATOR (FL190, PCV192, PCV193)

6.

OR198

2.

REGULATOR RETAINER

7.

FV194

8.

HV195

TEE-FITTING

3.

WASHER

9.

TEE-FITTING

PT102

4.

STAR WASHER

5.

CAPSCREW

4.

Loosen the nut connecting HV195 to the mounting bracket.

5.

Disconnect fittings (OR198 and FV194) from plumbing.

6.

Remove two capscrews, star washers, and washers, connecting the regulator retainer to the mounting bracket. Remove the regulator with fittings still attached.

7.

Disconnect the tee-fitting along with HV195 and PT102 from the regulator.

8.

Disconnect OR198 and FV194.

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Service procedures

Install 1.

Connect OR198 and FV194 to new regulator.

• For fuel cell systems up to and including S/N A2D1S01500R, see Figure 220.

• For fuel cell systems S/N A2D1S01501R and after, see Figure 221.

2.

Connect the tee-fitting along with HV195 and PT102 to the new regulator.

3.

Install assembled regulator and connect all fittings to plumbing.

• For fuel cell systems up to and including S/N A2D1S01500R, see Figure 220.

• For fuel cell systems S/N A2D1S01501R and after, see Figure 221.

4.

Use the two capscrews, star washers, and washers to install the regulator retainer back on to the mounting bracket.

5.

Tighten all fittings and check connections for leaks. See Leak check H2 plumbing.

6.

Install the high pressure compartment access panel.

7.

Insert the capscrews to secure access panel to fuel cell. See Figure 219.

8.

Use hex head wrench to tighten capscrews to 19.4 N•m (14.3 lbf ft.).

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Service procedures

Remove

Replacing FV194 and OR198

Scope To remove and replace FV194 and OR198.

All hydrogen must be vented from engine plumbing before servicing. See Vent hydrogen from engine plumbing lines.

Safety and warnings

1.

Locate the high pressure compartment access panel. See Figure 222.

NOTE: Do not perform this procedure unless you have fully read and understand this document.

1.

Read this manual and other specified documentation in their entirety before servicing this equipment.

2.

Before performing this procedure, ensure that you have the proper skill and specialty training needed to perform this procedure as it applies to both the Nuvera® Fuel Cell System and all supplemental equipment used. If you feel that you are not qualified to perform this procedure, contact Nuvera Fuel Cells LLC.

3.

Use caution when handling all parts in the fuel cell, as they may contain compressed hydrogen gas.

DANGER

Figure 222. High pressure compartment access panel

Hydrogen gas is flammable. Eliminate all ignition sources. Do not place an ignition source within 25 feet of this unit. DO NOT SMOKE WITHIN A 25 FOOT RADIUS OF THE FUEL CELL.

Tools required Nuvera part number

Description

Qty.

N/A

Hex head keys

1 set

1.

CAPSCREW

2.

ACCESS PANEL

2.

Use a 4 mm hex head key to remove the six capscrews securing the access panel to the fuel cell. Remove the access panel.

3.

Locate the regulator.

NOTE: This list does not include tools required for additional service procedures. Check the procedures below for necessary tools.

165

3.

HIGH PRESSURE COMPARTMENT

• For fuel cell systems up to and including S/N A2D1S01500R, see Figure 223.

• For fuel cell systems S/N A2D1S01501R and after, see Figure 224.

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Nuvera® Fuel Cell System C95A-33 Service Manual

Service procedures

Figure 223. Remove/install regulator, fuel cell systems up to and including S/N A2D1S01500R 1.

REGULATOR (FL190, PCV192, PCV193)

6.

OR198

2.

REGULATOR RETAINER

7.

FV194

8.

HV195

3.

WASHER

9.

4.

STAR WASHER

10.

5.

CAPSCREW

Figure 224. Remove/install regulator, fuel cell systems S/N A2D1S01501R and after 1.

REGULATOR (FL190, PCV192, PCV193)

6.

OR198

2.

REGULATOR RETAINER

7.

FV194

8.

HV195

TEE-FITTING

3.

WASHER

9.

TEE-FITTING

PT102

4.

STAR WASHER

5.

CAPSCREW

4.

Loosen the nut connecting HV195 to the mounting bracket.

5.

Disconnect fittings (OR198 and FV194) from plumbing.

6.

Remove two capscrews, star washers, and washers, connecting the regulator retainer to the mounting bracket. Remove the regulator with fittings still attached.

7.

Disconnect OR198 or FV194 from the regulator to replace.

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Service procedures

it applies to both the Nuvera® Fuel Cell System and all supplemental equipment used. If you feel that you are not qualified to perform this procedure, contact Nuvera Fuel Cells LLC.

Install 1.

Connect new OR198 or FV194 to the regulator.

2.

Install assembled regulator and connect all fittings to plumbing.

3.

• For fuel cell systems up to and including S/N A2D1S01500R, see Figure 223.

• For fuel cell systems S/N A2D1S01501R and after, see Figure 224.

3.

Use the two capscrews, star washers, and washers to install the regulator retainer back on to the mounting bracket.

4.

Tighten all fittings and check connections for leaks. See Leak check H2 plumbing.

5.

Install the high pressure compartment access panel. See Figure 222.

6.

Insert the capscrews to secure the access panel to fuel cell.

7.

Use the 4 mm hex head key to tighten capscrews to 19.4 N•m (14.3 lbf ft.).

Use caution when handling all parts in the fuel cell, as they may contain compressed hydrogen gas.

DANGER Hydrogen gas is flammable. Eliminate all ignition sources. Do not place an ignition source within 25 feet of this unit. DO NOT SMOKE WITHIN A 25 FOOT RADIUS OF THE FUEL CELL.

Tools required

Replacing the vent OK or watchdog timer (fuel cell systems up to and including S/N A2D1S01500R)

Nuvera part number

Description

Qty.

N/A

4 mm hex keys

1 ea.

N/A

Small slot head screwdriver

1

NOTE: This tool list does not include tools needed for additional procedures that may be needed for this service. Check the procedures listed below for all tools needed.

Scope

Prepare

To remove and install the vent OK timer or watchdog timer.

Safety and warnings

Before removing the vent OK timer or watchdog timer, the following procedures must be performed:

NOTE: Do not perform this procedure unless you have fully read and understand this document.

1.

Preparing the Nuvera fuel cell system for service

1.

Read this manual and other specified documentation in their entirety before servicing this equipment.

2.

Discharging and recharging the ultracapacitors

2.

Before performing this procedure, ensure that you have the proper skill and specialty training needed to perform this procedure as 167

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Nuvera® Fuel Cell System C95A-33 Service Manual

Service procedures

Remove 1.

2.

Remove the main cover. See Removing and installing the main cover.

Remove the engine sled from the fuel cell system. See Removing and installing the engine sled.

3.

Vent hydrogen from fuel system. See Vent hydrogen from engine plumbing lines.

4.

Remove the radiator from the engine sled.

See Removing and installing the radiator.

5.

Once the previous steps have been performed, use the 4 mm hex wrench to remove the Vent OK timer from the left side of the frame. See Figure 225.

6.

Remove all electrical connections from the timer. Make sure connections are all properly labeled before removal.

7.

Locate the watchdog timer on the right side of the frame assembly.

8.

Use the 4 mm hex key to remove the bolt holding the watchdog timer to the frame. See Figure 226.

Figure 226. Watchdog timer 9.

Remove all electrical connections from the watchdog timer. Make sure connections are all properly labeled before removal.

Install Figure 225. Remove Vent OK timer 1.

CONNECTORS

2.

MOUNTING BOLT

1.

Locate new watchdog or Vent OK timer.

Connect all electrical connections.

2.

Install the new timer.

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Service procedures

• If replacing the watchdog timer, insert the bolt into the timer and attach to the right side of the frame. Use the 4 mm hex key to tighten. See Figure 226.

• If replacing the Vent OK timer, insert the bolt into the timer and attach to the left side of the frame. Use the 4 mm hex key to tighten. See Figure 225.

3.

Install the radiator back on to the engine sled.

See Removing and installing the radiator.

4.

Install the engine sled back into the fuel cell system. See Vent hydrogen from engine plumbing lines.

5.

Re-install the main cover. See Removing and installing the main cover.

6.

Perform anode loop leak check. See Leak check anode loop.

7.

used. If you feel that you are not qualified to perform this procedure, contact Nuvera Fuel Cells LLC. 3.

DANGER Hydrogen gas is flammable. Eliminate all ignition sources. Do not place an ignition source within 25 feet of this unit. DO NOT SMOKE WITHIN A 25 FOOT RADIUS OF THE FUEL CELL.

Tools required

Recharge the ultracapacitors. See Discharging and recharging the ultracapacitors.

Replacing the vent OK or watchdog timer (fuel cell systems S/N A2D1S01501R and after)

To remove and install the vent OK timer or watchdog timer.

NOTE: Do not perform this procedure unless you have fully read and understand this document.

2.

Before performing this procedure, ensure that you have the proper skill and specialty training needed to perform this procedure as it applies to both the Nuvera® Fuel Cell System and all supplemental equipment

Description

Qty.

N/A

3 mm, 4 mm hex keys

1 ea.

N/A

Small slot head screwdriver

1

Prepare

Safety and warnings

Read this manual and other specified documentation in their entirety before servicing this equipment.

Nuvera part number

NOTE: This tool list does not include tools needed for additional procedures that may be needed for this service. Check the procedures listed below for all tools needed.

Scope

1.

Use caution when handling all parts in the fuel cell, as they may contain compressed hydrogen gas.

Before removing the compressor, the following procedures must be performed: 1.

Preparing the Nuvera fuel cell system for service

2.

Discharging and recharging the ultracapacitors

Remove 1.

169

Remove the main cover. See Removing and installing the main cover.

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Nuvera® Fuel Cell System C95A-33 Service Manual

Service procedures

2.

Vent hydrogen from the fuel system. See Vent hydrogen from engine plumbing lines

3.

Remove the engine sled from the fuel cell system. See Removing and installing the engine sled.

4.

Remove the radiator from the engine sled.

See Removing and installing the radiator.

5.

Once the previous steps have been performed, use the 3 mm hex key to remove the three screws holding the service panel to the back side of the engine sled wall. See Figure 227.

6.

Locate the Vent OK or watchdog timer on the inside of the service panel.

7.

Use the 4 mm hex key to remove the bolt holding the applicable timer to the service panel. See Figure 228.

Figure 228. Remove timer 1.

WATCHDOG TIMER

2.

VENT OK TIMER

8.

Remove all electrical connections from the applicable timer. Make sure connections are all properly labeled before removal.

Install 1.

Locate new watchdog or Vent OK timer.

Connect all electrical connections.

2.

Insert the bolt into the applicable timer and attach the timer to the inside of the service panel. See Figure 228.

3.

Use the 4 mm hex key to tighten the bolt.

4.

Set the new timer.

• The setting for the watchdog timer is 10.

See Figure 229.

Figure 227. Service panel

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Service procedures

• The settings for the Vent OK timer are T1:0.5 and T2:5. See Figure 230.

5.

Install the radiator back on to the engine sled.

See Removing and installing the radiator.

6.

Install the engine sled back into the fuel cell system. See Removing and installing the engine sled.

7.

Re-install the main cover. See Removing and installing the main cover.

8.

Perform anode loop leak check. See Leak check anode loop.

9.

Recharge the ultracapacitors. See Discharging and recharging the ultracapacitors.

Figure 229. Watchdog timer setting

Figure 230. Vent OK timer setting 1.

T1:0.5

2.

T2:5

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Nuvera® Fuel Cell System C95A-33 Service Manual

Periodic maintenance procedures

1000 hours

Procedure

Check wicking pad on radiator

See the procedure for Replacing the wicking filter in Nuvera® Fuel Cell System Service Manual.

Change air filter*▲↑

See the procedure for Replacing the air filter in Nuvera® Fuel Cell System Service Manual.

Top off coolant

See the procedure for Draining and filling coolant in Nuvera® Fuel Cell System Service Manual.

Change DI filter

See the procedure for Replacing the coolant filter in Nuvera® Fuel Cell System Service Manual.

Check access panel screens *In dusty or dirty environments, use compressed air to blow out the radiator each time the air filter is changed. ↑When changing the air filter, inspect compressor for signs of damage or oil leakage. Repair as necessary. ▲In environments with poor air quality or a detectable chemical smell, change air filter every 250 hours.

Safety Performance Checks Perform the following safety performance checks every 2000 hours DPS Switch - Ensure that if air is removed that DPS opens up.

Engage emergency stop on HMI to confirm functionality of interlock circuit Test F07 functionality for small radiator fans.

Perform anode loop leak check Perform manual leak check of high pressure H2 plumbing

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Special Tools

Special tools Part Number

Description

Part Number

Description

31004815

Stack placement bracket (fixture)

31004824

Stack bolting

31004844

CAN interface (Kvaser)

31004773

Portable load bank (500A)

31004774

Portable load bank (single load)

31004775

Power supply

31004846

31004776

Power supply test lead

Combustible gas detector CAN interface (Vector)

31004777

Depth marking tool (1/4")

31004847 31004848

Protective apparel kit

31004849

Multimeter tool

31004778

Depth marking tool (3/8")

31004850

CAN interface (Vector)

31004779

Liquid leak detector

31004853

31004780

Gap inspection gauge (1/4", 3/8", 1/2")

22 mm socket (heater removal)

31004855

Regulator valve

31004781

Tube deburring tool (3/16"-1 1/2")

31004591

Coolant Fill Kit

31003042

Safety Cover

31004782

Tube cutter tool

31000818

Display

31004783

Pre-swage, 1/4" OD tube

31002424

Wire Harness-External HMI

31004812

Pre-swage, 3/8" OD tube

31000152

Display-Parker Chart-Lifting Eye

31004813

Lifting eye kit (class I and II)

31001569 31006596

Kit-DC/DC

31004814

Trifecta cover

31007157

Kit-Lifting Device Tool

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Notes

| | |

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Nuvera Fuel Cells LLC 129 Concord Road, Bldg. 1 Billerica, MA 01821 USA Tel: (617) 245-7500