PDF DOWNLOAD: Nuvera N1800V36 N1821V36 N1800V48 N1824V48 Fuel Cell System Service Manual

Service Manual Fuel Cell System N1800V36/N1821V36/N1800V48/ N1824V48

31009687 | 06/2023

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. 2023 All rights reserved.

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Nuvera® Fuel Cell System N1800V36/N1821V36/ N1800V48/N1824V48 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 Hydrogen fueling concerns. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Swagelok® fitting procedures Swagelok® procedures. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Scope. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Safety and warnings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Tools required. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Initial assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5 Gauging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6 Reassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Preparing for service and maintenance Removing and installing the cover panels. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Scope. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Safety and warnings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Parts and tools required. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Remove. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Install. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Disconnecting the batteries. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 Scope. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 Safety and warnings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 Parts and tools required. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11 Main battery disconnect. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 Main battery connect. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 Low voltage (5 amp) battery disconnect. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12 Low voltage (5 amp) battery connect. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 Updating the software. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 Scope. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 Safety and warnings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 Tools required. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 Update software. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 I

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Contents

Nuvera® Fuel Cell System N1800V36/N1821V36/ N1800V48/N1824V48 Service Manual

Preparing for service and maintenance Installing the Winflash software. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 Scope. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 Safety and warnings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 Install Winflash software. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 Open and close the tank valve. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .26 Scope. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 Safety and warnings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 Parts and tools required. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .26 Close the tank valve. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 Open the tank valve. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 Service procedures Replacing the air filter. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 Scope. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 Safety and warnings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 Parts and tools required. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .27 Prepare. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 Remove. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 Install. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 Replacing the DI filter. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28 Scope. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28 Safety and warnings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28 Parts and tools required. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .28 Prepare. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28 Remove. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28 Install. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 Drain and fill coolant. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31 Scope. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31 Safety and warnings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31 Parts and tools required. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .31 Prepare. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31 Drain. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31 Fill coolant. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .33 Replacing the main battery. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34 Scope. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34 Safety and warnings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34 Parts and tools required. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .34 II

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Nuvera® Fuel Cell System N1800V36/N1821V36/ N1800V48/N1824V48 Service Manual

Service procedures Prepare. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35 Remove. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35 Remove. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36 Install. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37 Install. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37 Replacing the 12V batteries. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38 Scope. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38 Safety and warnings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38 Parts and materials required. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .38 Prepare. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38 Remove. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38 Install. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39 Storing the Lithium-ion batteries. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39 Replacing the DC/DC assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42 Scope. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42 Safety and warnings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42 Parts and tools required. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .42 Prepare. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42 Remove. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42 Install. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45 Replacing the main PCB and system controller (STW). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46 Scope. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46 Safety and warnings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46 Parts and tools required. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .46 Prepare. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46 Remove. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46 Install. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48 Replacing the data port. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .49 Scope. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49 Safety and warnings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49 Parts and tools required. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .49 Prepare. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49 Remove. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49 Install. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50 Replacing the start button. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51 Scope. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51 Safety and warnings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51 Parts and tools required. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .51 III

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Contents

Nuvera® Fuel Cell System N1800V36/N1821V36/ N1800V48/N1824V48 Service Manual

Service procedures Prepare. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51 Remove. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51 Install. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52 Replacing the emergency stop button. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53 Scope. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53 Safety and warnings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53 Parts and tools required. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .53 Prepare. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53 Remove. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53 Install. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53 Replacing the E-Stop contact block. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .55 Scope. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55 Safety and warnings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55 Parts and tools required. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .55 Prepare. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55 Remove. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55 Install. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56 Replacing the power cables. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57 Scope. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57 Safety and warnings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57 Parts and tools required. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .57 Prepare. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57 Remove. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57 Install. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58 Replacing the hydrogen leak sensors. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59 Scope. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59 Safety and warnings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59 Parts and tools required. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .59 Prepare. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59 Remove AS5 sensor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .59 Remove AS6 sensor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .60 Install AS6 sensor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .60 Install AS5 sensor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .60 Replacing the air compressor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62 Scope. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62 Safety and warnings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62 Parts and tools required. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .62 Prepare. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62 IV

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Contents

Nuvera® Fuel Cell System N1800V36/N1821V36/ N1800V48/N1824V48 Service Manual

Service procedures Remove. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62 Install. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63 Replacing the air compressor motor controller. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65 Scope. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65 Safety and warnings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65 Parts and tools required. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .65 Prepare. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65 Remove. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65 Install. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66 Replacing the coolant pump. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68 Scope. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68 Safety and warnings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68 Parts and tools required. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .68 Parts and tools required. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .68 Prepare. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68 Remove. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69 Install. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69 Replacing the coolant filter/manifold. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70 Scope. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70 Safety and warnings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70 Parts and tools required. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .70 Prepare. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70 Remove. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70 Remove the particulate filter. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71 Install the particulate filter. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72 Install. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72 Replacing the radiator. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74 Scope. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74 Safety and warnings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74 Parts and tools required. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .74 Prepare. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74 Remove. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74 Clean. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75 Install. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76 Replacing the fuel cell stack. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77 Scope. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77 Safety and warnings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77 Parts and tools required. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .77 V

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Contents

Nuvera® Fuel Cell System N1800V36/N1821V36/ N1800V48/N1824V48 Service Manual

Service procedures Prepare. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77 Remove. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77 Install. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80 Replacing the truck contactor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82 Scope. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82 Safety and warnings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82 Parts and tools required. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .82 Prepare. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82 Remove. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82 Install. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83 Replacing the battery contactor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84 Scope. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84 Safety and warnings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84 Parts and tools required. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .84 Prepare. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84 Remove. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84 Install. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85 Replacing the DC/DC contactor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86 Scope. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86 Safety and warnings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86 Parts and tools required. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .86 Prepare. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86 Remove. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86 Install. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87 Replacing the current transducer. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88 Scope. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88 Safety and warnings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88 Parts and tools required. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .88 Prepare. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88 Remove. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88 Install. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89 Replacing the fuses. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91 Scope. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91 Safety and warnings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91 Prepare. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91 Remove/Install. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91 Replacing the humidifier. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .94 Scope. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94 VI

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Service procedures Safety and warnings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94 Parts and tools required. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .94 Prepare. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94 Remove. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94 Install. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96 Replacing the hydrogen fill line. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97 Scope. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97 Safety and warnings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97 Parts and tools required. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .97 Prepare. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97 Remove. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97 Install. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99 Replacing the hydrogen fill port. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101 Scope. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101 Safety and warnings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101 Parts and tools required. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101 Prepare. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101 Remove. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101 Install. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102 Replacing the hydrogen regulator. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103 Scope. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103 Safety and warnings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103 Parts and tools required. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103 Prepare. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103 Remove. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104 Install. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105 Replacing the hydrogen recirculation pump. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .106 Scope. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106 Safety and warnings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106 Parts and tools required. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106 Prepare. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106 Remove. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106 Install. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107 Replacing the hydrogen fuel tank. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109 Scope. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109 Safety and warnings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109 Parts and tools required. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109 Prepare. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109 VII

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Service procedures Remove. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110 Install. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111 Replacing the hydrogen purge valve. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112 Scope. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112 Safety and warnings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112 Parts and tools required. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112 Parts and tools required. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112 Prepare. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113 Remove. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113 Install. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113 Replacing the hydrogen pressure sensors. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .115 Scope. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115 Safety and warnings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115 Parts and tools required. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115 Prepare. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115 Remove. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115 Install. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116 Replacing the coolant temperature and pressure sensors. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117 Scope. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117 Safety and warnings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117 Parts and tools required. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117 Prepare. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117 Remove. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117 Install. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119 Replacing the cathode Mass Air Flow (MAF) sensor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120 Scope. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120 Safety and warnings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120 Parts and tools required. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120 Prepare. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120 Remove. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120 Install. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121 Replacing the cathode temperature and pressure (TMAP) sensors. . . . . . . . . . . . . . . . . . . . . . . . . . . .122 Scope. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122 Safety and warnings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122 Parts and tools required. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122 Prepare. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122 Remove. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122 Install. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124 VIII

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Service procedures Replacing the dewatering connector. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125 Scope. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125 Safety and warnings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125 Parts and tools required. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125 Prepare. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125 Remove. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125 Install. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126 Replacing the antenna. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127 Scope. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127 Safety and warnings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127 Parts and tools required. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127 Remove. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127 Install. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128 Replacing the water reservoir. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129 Scope. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129 Safety and warnings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129 Parts and materials required. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .129 Prepare. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129 Remove. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129 Install. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131 Remove. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 132 Install. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134 Replacing the main electrical box. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 136 Scope. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 136 Safety and warnings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 136 Parts and materials required. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .136 Prepare. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 136 Remove. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 136 Install. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 137 Replacing the 24V DCDC. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 138 Scope. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 138 Safety and warnings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 138 Parts and materials required. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .138 Prepare. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 138 Remove. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 138 Install. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 139 Replacing the pre-charge resistor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 140 Scope. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 140 IX

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Service procedures Safety and warnings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 140 Parts and tools required. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 140 Prepare. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 140 Remove. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 140 Install. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 141 Storage procedures Storage. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .142 Short-term storage. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 142 Mid-term storage. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 142 Long-term storage. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .143 Commissioning the Nuvera® fuel cell system after storage. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .144 Periodic maintenance procedures Periodic maintenance procedure schedule. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .145 Clean and inspect radiator. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 146 Scope. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 146 Safety and warnings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 146 Inspect and clean. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 146 Coolant maintenance and filtration. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 147 Safety and warnings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 147 Inspect and clean. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 147 Visual coolant check. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 150 Scope. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 150 Safety and warnings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 150 Parts and tools required. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 150 Procedure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 150 Procedure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 151 Coolant conductivity check. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 152 Scope. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 152 Safety and warnings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 152 Parts and tools required. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 152 Prepare. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 152 Procedure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 152 H2 pressure relief. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .154 Scope. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 154 Safety and warnings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 154 X

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Periodic maintenance procedures Prepare. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 154 Procedure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 154 Inspect the emergency stop button. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 156 Scope. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 156 Safety and warnings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 156 Prepare. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 156 Inspect. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 156 Special Tools Special tools. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 157

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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

Tighten the nut. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5 Gap inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Marking line. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Insert tube into fitting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6 Top panel. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8 Left hand side panel. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Right hand side panel. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Front panel. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Battery busbars. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 Low voltage battery. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 Low voltage battery disconnect. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 Software connector. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16 Download Nuvera software. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16 Extract files. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 Flash software to controller. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 Integration harness switch. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 Confirm "TestNet". . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 Select PCAN-USB. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 Do not start...screen. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 Download Winflash software. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 Extract Winflash files. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 Winflash install wizard. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 Choose destination. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 Setup type. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .22 Setup wizard. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 Install driver. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 Driver installation wizard. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 Select setup type. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 Select name. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 PEAK website. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 Extract files. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 PEAK Drivers setup. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 Custom setup. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 Tank valve opening. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 Air filter. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 DI filter and coolant particulate filter. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29 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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DI filter hoses. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29 DI filter. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .30 Radiator cap. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32 DI filter and coolant particulate filter. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32 Radiator drain plug. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32 Fill coolant. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .33 Battery and bus bars. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35 Communication connector. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36 Battery mounting screws. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36 Disconnect main battery. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36 Battery bracket. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39 Battery terminals. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39 Battery label. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40 Depth of discharge vs. battery cell voltage. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .41 DC/DC location. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .43 Attaching bus bars. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .43 DC/DC mounting bolts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44 DC/DC connectors. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45 STW harness. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47 PCB electrical connectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47 PCB mounting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .47 STW mounting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48 Data port connector. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50 Data port nut. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50 Start button nut. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51 E-stop button. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53 E-stop contact block. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56 Positive terminal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58 Negative terminal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58 AS5 sensor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60 AS6 sensor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60 Compressor connectors. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63 Compressor hoses. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63 Compressor front mounting screws. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .63 Compressor motor controller connectors. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66 Compressor mounting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66 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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Terminal connections. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67 Coolant pump and connections. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69 Coolant hoses. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69 Bracket and screws. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71 Filter/manifold hoses. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71 Coolant particulate filter. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72 Filter orientation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72 Radiator and hoses. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75 Radiator connectors. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75 Positive bus bar. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78 Negative bus bar. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78 Stack hoses right side. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79 Stack hoses left side. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79 Fuel cell stack bottom mounting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80 Fuel cell stack side mounting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80 Stack inlet and outlet fittings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80 Truck contactor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83 Battery contactor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85 DC/DC contactor mounting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87 DC/DC contactor and bus bars. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87 Current transducer mounting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89 Current transducer subassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89 Electrical box fuses. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92 Other fuses. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93 Humidifier hose clamps. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95 Humidifier mounting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .95 Humidifier and hoses. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96 Hydrogen fill tube. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98 Hydrogen fill port switch connector. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98 Fill line remove. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .99 Swaged nuts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99 Fill port harness connector. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102 Hydrogen fill port remove. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102 Regulator connections. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104 Regulator remove. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104 Recirculation pump connections. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107 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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Recirculation pump hoses. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107 Hydrogen recirculation pump fittings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108 Upper and lower casting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110 Regulator connections. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110 Upper casting removed. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111 Purge valve connector. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113 Purge valve fittings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113 High pressure sensor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116 Low pressure sensors. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116 Coolant temperature sensor at pump outlet. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118 Coolant temperature sensor at fuel cell outlet. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118 Coolant pressure sensor at pump outlet. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118 Coolant pressure sensor outlet. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119 Coolant pressure sensor inlet. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119 MAF sensor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .121 TMAP sensor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123 TMAP sensors at radiator. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123 TMAP sensors at fuel cell stack. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .124 Dewatering connector fitting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126 Antenna/modem. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128 Water reservoir connections. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .130 Reservoir bias hose. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130 Air manifold connections. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .131 Mounting screws. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131 Fill port harness connector. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 132 Start button. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133 J1, J2, J3 connectors. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133 Operator interface. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133 Positive bus bar. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134 Water reservoir. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134 Water reservoir mounting (rear). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134 Water reservoir mounting (center). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134 Main electrical box connections. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .137 Main electrical box. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 137 24V DCDC connections. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .139 24V DCDC screws. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 139 XV

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Contents

Nuvera® Fuel Cell System N1800V36/N1821V36/ N1800V48/N1824V48 Service Manual

List of Figures Figure 145 146 147 148 149 150 151 152 153 154

Title

Page

Pre-charge resistor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 141 Water reservoir drain. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 142 Battery busbars. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 143 DI filter and drain. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 148 DI filter and drain. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 148 Radiator cap. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 151 Radiator cap. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 151 DI filter and coolant particulate filter. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 153 Hydrogen pressure relief. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 155 E-stop button. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 156

XVI

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Contents

Nuvera® Fuel Cell System N1800V36/N1821V36/ N1800V48/N1824V48 Service Manual

List of Tables Table 1 2 3 4 5

Title

Page

System fuses. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .93 Coolant and Deionizing filter specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 148 Service intervals for coolant system components. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 148 Required tools. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 152 Service intervals for coolant system components. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 153

XVII

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Nuvera® Fuel Cell System N1800V36/N1821V36/ N1800V48/N1824V48 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 N1800V36/N1821V36/ N1800V48/N1824V48 Service Manual

General Information General hazards, warnings, and cautionary statements 1.

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.

2.

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.

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.

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.

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.

8.

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

CAUTION

3.

shut down the system IMMEDIATELY using the emergency stop button if it is safe to do so.

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

13. The fuel cell system is not rated for use below 2°C (36°F) or above 41°C (106°F). 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.

15. Properly dispose of Lithium-ion (Li-ion) batteries and battery chargers. Components marked with the 'recycle' symbol must be taken to an authorized waste recycling center. Used batteries must not be mixed with domestic or industrial refuse or burned.

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 your service provider.

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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General Information

Nuvera® Fuel Cell System N1800V36/N1821V36/ N1800V48/N1824V48 Service Manual

Hydrogen-specific concerns The Nuvera® Fuel Cell System (FCS) 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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General Information

Nuvera® Fuel Cell System N1800V36/N1821V36/ N1800V48/N1824V48 Service Manual

Hydrogen fueling concerns •

Incorrect refueling could result in hydrogen leak, rupture, or fire.

•

Refuel only from dispensers that comply with the SAE J2601-3 protocol and NFPA 2. Do not refuel from bus, automotive, or other dispensers.

• H35 hydrogen fuel only. SAE J2719 or equivalent hydrogen fuel quality only. Do not exceed 35 MPa (5000 psi).

4

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Nuvera® Fuel Cell System N1800V36/N1821V36/ N1800V48/N1824V48 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.

2.

3.

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

Initial assembly

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 your service provider.

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

1.

Fully insert the tube into the fitting and against the shoulder. Rotate the nut to fingertight.

2.

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

3.

Mark the nut at the 6 o'clock position.

4.

While holding the fitting body steady, tighten the nut 1 1/4 turns to the 9 o'clock position.

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.

Tools required Nuvera part number

Description

31004780

Swagelok® gap inspection tool

Qty. Figure 1. Tighten the nut 1

5

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Nuvera® Fuel Cell System N1800V36/N1821V36/ N1800V48/N1824V48 Service Manual

Swagelok® fitting procedures

Gauging 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 2.

Figure 3. Marking line 2.

Insert the tube with preswaged ferrules into the fitting until the front ferrule seats against the fitting body. See Figure 4.

Figure 2. Gap inspection If the gauge will not enter the gap, the fitting is sufficiently tightened. If the gauge will enter the gap, additional tightening is required.

Reassembly

WARNING Always depressurize the system before disassembling a Swagelok tube fitting.

Figure 4. Insert tube into fitting 3.

NOTE: Swagelok tube fittings may be disassembled and reassembled multiple times.

1.

Prior to disassembly, mark the tube at the back of the nut and mark a line across the nut and fitting body flats. Use these marks to ensure that you return the nut to the previously pulled-up position. See Figure 3.

Hold the fitting body steady and rotate the nut with a wrench to the previously pulled up position, as indicated by the marks on the tube and flats. At this point, you will feel a signifcant increase in resistance. Tighten the nut 1/12 of a turn or 1/2 of a flat.

CAUTION Do not use the Swagelok gap inspection gauge with reassembled fittings.

6

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Nuvera® Fuel Cell System N1800V36/N1821V36/ N1800V48/N1824V48 Service Manual

Preparing for service and maintenance Removing and installing the cover panels

Nuvera part number

Description

Qty.

31009990

1

To remove the cover panels from the Fuel Cell System (FCS), prior to service on FCS components.

Right hand side panel

31009993

Left hand side panel

1

Safety and warnings

31009992

Top panel

1

Scope

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

1.

2.

3.

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

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

Remove

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 your service provider.

NOTE: When removing the top panel, make sure the power cables and truck connection harness are out of the way, so as not to be damged during removal.

Top panel 1.

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

Use a Torx driver to remove the six screws retaining the top panel to the FCS enclosure.

See Figure 5.

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 tools required Nuvera part number

Description

Qty.

N/A

Torx driver set

1

N/A

Torque wrench

1

31010017

Front panel

1

7

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Preparing for service and maintenance

Nuvera® Fuel Cell System N1800V36/N1821V36/ N1800V48/N1824V48 Service Manual

Figure 5. Top panel 1.

TOP PANEL

2.

2.

Lift the top panel up to remove from the FCS. See Figure 5.

Figure 6. Left hand side panel

SCREW

1.

SCREW

2.

LEFT HAND SIDE PANEL

2.

Pull the left hand side panel free to remove from the FCS. See Figure 6.

Left hand upper side panel

Right hand upper side panel

1.

1.

Use a Torx driver to remove the six screws retaining the right hand side panel to the FCS enclosure. See Figure 7.

2.

Pull the right hand side panel free to remove from the FCS. See Figure 7.

Use a Torx driver to remove the eight screws retaining the left hand side panel to the FCS enclosure. See Figure 6.

8

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Preparing for service and maintenance

Nuvera® Fuel Cell System N1800V36/N1821V36/ N1800V48/N1824V48 Service Manual

Figure 7. Right hand side panel 1.

RIGHT HAND SIDE PANEL

2.

Figure 8. Front panel

SCREW

1.

Use a Torx driver to remove the eleven screws retaining the front panel to the FCS enclosure. See Figure 8.

2.

Pull the front panel free to remove from the FCS. See Figure 8.

2.

FRONT PANEL

Install

Front panel 1.

SCREW

NOTE: If replacing any of the panels with a new panel, see Parts and tools required table above or Parts Manual for correct part number.

Front panel 1.

Align the front panel in place on the FCS. See Figure 8.

2.

Insert the eleven screws to retain the front panel to the FCS enclosure. See Figure 8.

3.

Use the torque wrench to tighten. Torque to 5 N•m (3.7 lbf ft.).

Right hand side panel

9

1.

Align the right hand side panel in place on the FCS. See Figure 7.

2.

Insert the six screws to retain the right hand side panel to the FCS enclosure. See Figure 7.

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Preparing for service and maintenance 3.

Nuvera® Fuel Cell System N1800V36/N1821V36/ N1800V48/N1824V48 Service Manual

Use the torque wrench to tighten. Torque to 5 N•m (3.7 lbf ft.).

Left hand upper side panel 1.

Align the left hand side panel in place on the FCS. See Figure 6.

2.

Insert the eight screws to retain the left hand side panel to the FCS enclosure. See Figure 6.

3.

Use the torque wrench to tighten. Torque to 5 N•m (3.7 lbf ft.).

Top panel 1.

Lower the top panel on to the FCS. See Figure 5.

2.

Insert the six screws to retain the top panel to the FCS enclosure. See Figure 5.

3.

Use the torque wrench to tighten. Torque to 5 N•m (3.7 lbf ft.).

10

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Preparing for service and maintenance

Nuvera® Fuel Cell System N1800V36/N1821V36/ N1800V48/N1824V48 Service Manual

Parts and tools required

Disconnecting the batteries

Scope To disconnect the main 36/48V battery and the low voltage (5 amp) battery from the Fuel Cell System (FCS) to prepare for service.

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 your service provider.

3.

Nuvera part number

Description

Qty.

N/A

Torque wrench

1

N/A

Hex bit set

1

N/A

Insulated socket wrench set

1

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

NOTE: The following procedures must be performed before attemtpting any service procedure on the fuel cell system.

Main battery disconnect Mid-term storage is defined as storage time that will exceed 1 month in duration, but not to exceed 3 months. To properly prepare a unit for mid-term storage the following steps must be taken:

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.

11

1.

Remove the left hand upper side panel. See Removing and installing the cover panels.

2.

Disconnect the negative bus bar from the main battery (voltage dependent upon system specification). See Figure 9.

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Nuvera® Fuel Cell System N1800V36/N1821V36/ N1800V48/N1824V48 Service Manual

Preparing for service and maintenance

Figure 9. Battery busbars 1.

MAIN BATTERY

2.

POSITIVE BUSBAR

3.

NEGATIVE BUSBAR

Main battery connect

Low voltage (5 amp) battery disconnect

1.

1.

Remove the right hand upper side panel.

2.

Locate the low voltage battery. See Figure 10.

2.

Insert the busbar screws back into contactor and battery terminal. Torque to 10 N-m (7.4 ft-lbs).

Install the left hand upper side panel and tighten screws. Torque to 5 N-m (3.7 ft-lbs).

12

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Nuvera® Fuel Cell System N1800V36/N1821V36/ N1800V48/N1824V48 Service Manual

Preparing for service and maintenance

Figure 10. Low voltage battery 1.

LOW VOLTAGE BATTERY

3.

Disconnect the low voltage (12V) battery by removing the 5A fuse from the inline fuse block or disconnecting the 2-pin battery connector. See Figure 11.

13

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Nuvera® Fuel Cell System N1800V36/N1821V36/ N1800V48/N1824V48 Service Manual

Preparing for service and maintenance

Figure 11. Low voltage battery disconnect 1.

5A FUSE

2.

BATTERY CONNECTOR

Low voltage (5 amp) battery connect 1.

Connect the low voltage battery by installing the 5A fuse to the inline fuse block or connect the 2-pin battery connector. See Figure 11.

2.

Install the right hand upper side panel and tighten screws. Torque to 5 N-m (3.7 ft-lbs).

14

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Nuvera® Fuel Cell System N1800V36/N1821V36/ N1800V48/N1824V48 Service Manual

Preparing for service and maintenance Updating the software

Nuvera part number

Scope

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

2.

3.

Qty.

from HYPASS or Yale Axcess Online)

To update the software on the Fuel Cell System (FCS).

1.

Description

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 your service provider.

31009515

CableUSB2CAN Peak systems dongle

1

31010680

120 Ohm resistor block

1

31009516

12 pin CableUser Interface Harness

1

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

Update software

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

1.

Confirm the Fuel Cell System is powered off and the E-stop is engaged.

2.

Locate the connector port for the software on the outside of the FCS.

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

Laptop with Kefex Winflash (download

1

15

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Nuvera® Fuel Cell System N1800V36/N1821V36/ N1800V48/N1824V48 Service Manual

Preparing for service and maintenance

3.

Connect the dongle (31009515) to the connector port with the 120 Ohm resistor block (31010680) and 12 pin harness (31009516).

4.

Set the switch on the programming harness to the open position (toggle switch lever pointing away from the wiring).

5.

Download the Nuvera Controllers Software file from Yale Axcess online. See Figure 13.

Figure 12. Software connector 1.

SOFTWARE CONNECTOR PORT

Figure 13. Download Nuvera software

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Preparing for service and maintenance 6.

Nuvera® Fuel Cell System N1800V36/N1821V36/ N1800V48/N1824V48 Service Manual

On the Select a Destination and Extraction Files screen, select/browse to a folder whre the files will be installed. Select Extract. See Figure 14.

7.

To flash the software: • Push the Select button to select hex file (item1, Figure 15).

• In the Company ID field, type "IFC". See item 2, Figure 15.

• Select Flash Node button (item 3, Figure 15). Locate the switch on the integration harness and be ready to flip the switch from "off" to "on". See Figure 16.

• Flip the switch to "on" as soon as the green progress (item 4, Figure 15) bar begins to move.

Figure 14. Extract files

17

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Preparing for service and maintenance

Nuvera® Fuel Cell System N1800V36/N1821V36/ N1800V48/N1824V48 Service Manual

Figure 15. Flash software to controller 1.

HEX FILE FIELD SELECT BUTTON

4.

PROGRESS BAR

2.

COMPANY ID FIELD

5.

COMM DLL FIELD SELECT BUTTON

3.

FLASH NODE BUTTON

6.

BITRATE FIELD

18

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Preparing for service and maintenance

Nuvera® Fuel Cell System N1800V36/N1821V36/ N1800V48/N1824V48 Service Manual

Figure 18. Select PCAN-USB 10. Select "Do not start (stay in sleep mode)". See Figure 19.

Figure 16. Integration harness switch 8.

Click Yes to confirm. See Figure 17.

Figure 19. Do not start...screen 11. Restart the unit. Programming is complete.

Figure 17. Confirm "TestNet" 9.

Select PCAN-USB and click OK button. See Figure 18.

19

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Nuvera® Fuel Cell System N1800V36/N1821V36/ N1800V48/N1824V48 Service Manual

Preparing for service and maintenance Installing the Winflash software

used. If you feel that you are not qualified to perform this procedure, contact your service provider.

Scope 3.

To install the Winflash software on a laptop computer.

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

Safety and warnings

DANGER

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

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.

Install Winflash software 1.

Download the Winflash file from or Yale Axcess online. See Figure 20.

Figure 20. Download Winflash software 2.

Extract zipped files to a directory of your choice. See Figure 21.

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Preparing for service and maintenance

Nuvera® Fuel Cell System N1800V36/N1821V36/ N1800V48/N1824V48 Service Manual

Figure 21. Extract Winflash files 3.

From the install wizard, click NEXT. See Figure 22. Step through the wizard to view the Supported Soft-Hardware screen and the License Agreement.

Figure 22. Winflash install wizard

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Preparing for service and maintenance 4.

Nuvera® Fuel Cell System N1800V36/N1821V36/ N1800V48/N1824V48 Service Manual

On the Choose Destination Location screen, select/browse to a folder whre the files will be installed. Select Next. See Figure 23.

Figure 25. Setup wizard 7.

Figure 23. Choose destination 5.

The driver will now be installed. See Figure 26.

Choose Setup Type. Select Next. See Figure 24.

Figure 26. Install driver 8.

Figure 24. Setup type 6.

Step through the wizard to complete PEAK CAN Driver installation. See Figure 27.

To choose interface, select PEAKSystem...CAN interface. Select Next. See Figure 25.

22

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Preparing for service and maintenance

Nuvera® Fuel Cell System N1800V36/N1821V36/ N1800V48/N1824V48 Service Manual 10. Write TestNet as Network Config. See Figure 29.

Figure 27. Driver installation wizard 9.

Select PCAN USB as Setup Type. See Figure 28.

Figure 29. Select name NOTE: You may experience an issue with Winflash not recognizing the dongle. In this situation, it may be helpful to visit www.peaksystem.com and install the drivers.

11. If installing the driver from the website, go to www.peak-system.com. Select the Download button. See Figure 30.

Figure 28. Select setup type

23

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Nuvera® Fuel Cell System N1800V36/N1821V36/ N1800V48/N1824V48 Service Manual

Preparing for service and maintenance

Figure 30. PEAK website 12. On the Select a Destination and Extraction Files screen, select/browse to a folder whre the files will be installed. Select Extract. See Figure 31.

Figure 32. PEAK Drivers setup 14. Choose custom setup. Select Next. See Figure 33.

Figure 31. Extract files 13. Step through the wizard to setup the PEAK CAN Driver. See Figure 32.

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Preparing for service and maintenance

Nuvera® Fuel Cell System N1800V36/N1821V36/ N1800V48/N1824V48 Service Manual

Figure 33. Custom setup 15. Step through the rest of the setup wizard to complete setup.

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Nuvera® Fuel Cell System N1800V36/N1821V36/ N1800V48/N1824V48 Service Manual

Preparing for service and maintenance Open and close the tank valve

Scope

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

To open and close the hydrogen fuel tank valve.

Close the tank valve

Safety and warnings

1.

Locate the tank valve opening on the front cover of the Fuel Cell System. See Figure 34.

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 your service provider.

3.

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

Figure 34. Tank valve opening

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.

Description

Qty.

N/A

5.5 mm, 1/4" drive socket

1

Insert the 5.5 mm drive socket through the valve opening and into the screw.

3.

Turn the screw clockwise until it stops, to close the tank valve.

Open the tank valve

Parts and tools required Nuvera part number

2.

26

1.

Locate the tank valve opening on the front cover of the Fuel Cell System. See Figure 34.

2.

Insert the 5.5 mm drive socket through the valve opening and into the screw.

3.

Turn the screw counterclockwise until it stops, to open the tank valve.

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Nuvera® Fuel Cell System N1800V36/N1821V36/ N1800V48/N1824V48 Service Manual

Service procedures

Prepare

Replacing the air filter

Scope To remove the air filter from the Fuel Cell System (FCS) and replace with new.

Safety and warnings

1.

Remove the FCS from the lift truck. Confirm the FCS is powered off.

2.

Remove the front panel. See Removing and installing the cover panels.

Remove

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 your service provider.

3.

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

1.

With the front panel removed, locate the air filter. See Figure 35.

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 35. Air filter 2.

Parts and tools required

The air filter is held in place by a barb press fit into a mating port. Pull and twist the air filter from the mating port to remove the filter.

See Figure 35.

Nuvera part number

Description

Qty.

Install

31009984

Air filter

1

1.

Locate the new air filter.

2.

Insert the new air filter into place in the FCS. See Figure 35.

3.

Install the front panel. See Removing and installing the cover panels.

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

27

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Nuvera® Fuel Cell System N1800V36/N1821V36/ N1800V48/N1824V48 Service Manual

Service procedures Replacing the DI filter

Scope To remove the deionization (DI) filter from the Fuel Cell System (FCS) and replace with new.

Nuvera part number

Description

Qty.

N/A

Torque wrench

1

N/A

1/2 in wide PTFE sealing tape

1

N/A

Hose clamp pliers

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.

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

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 your service provider.

Prepare

3.

1.

Remove the FCS from the lift truck. Confirm the FCS is powered off.

2.

Remove the right hand upper side panel. See Removing and installing the cover panels.

Remove

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

NOTE: The following procedure describes the process for removing the deionization (DI) filter. If removing any of the attaching parts, see the Parts Manual.

DANGER

1.

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.

With the right hand upper side panel removed, locate the DI filter. See Figure 36.

Parts and tools required Nuvera part number

Description

Qty.

31009971

DI filter

1

N/A

T25 Torx bit

1

N/A

Bit driver

1

N/A

7 mm socket

1 28

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Nuvera® Fuel Cell System N1800V36/N1821V36/ N1800V48/N1824V48 Service Manual

Service procedures

Figure 36. DI filter and coolant particulate filter 1.

2.

DI FILTER

2.

Figure 37. DI filter hoses

COOLANT PARTICULATE FILTER

If hose clamp pliers are available, clamp the upper and lower hose (item 1, Figure 37) to avoid excess coolant spillage. If pliers are not available, drain the coolant. See Drain and fill coolant.

29

1.

UPPER AND LOWER HOSE

2.

SCREWS

3.

Use the T25 torx bit to remove the 3 screws retaining the DI filter and bracket. See Figure 37.

4.

Use the 7 mm socket wrench to remove the hose clamps from the upper and lower hoses.

See Figure 38.

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Nuvera® Fuel Cell System N1800V36/N1821V36/ N1800V48/N1824V48 Service Manual

Service procedures

5.

Connect the hoses to the fittings and install the hose clamps. Tighten the hose clamps.

6.

Insert the 3 screws to retain the DI filter and bracket to the FCS. See Figure 37.

7.

Use the T25 torx bit to tighten to standard torque.

8.

Install the right hand upper side panel. See Removing and installing the cover panels.

Figure 38. DI filter 1.

HOSE CLAMPS

3.

BRACKET

2.

SCREWS

4.

FILTER CLAMP

5.

Remove the hoses.

6.

Remove the DI filter and bracket from the FCS.

7.

Remove the 2 screws and nuts attaching the filter clamps to the bracket and remove the filter. See Figure 38.

Install 1.

Locate the new DI filter.

2.

Install fittings on the new DI filter, by applying 5 wraps of PTFE tape the the threads of the fittings, and install into the NPT ports on the new DI filter. Tighten with fingers ensuring at least 1 thread is showing.

3.

Insert the DI filter into the filter brackets. See Figure 38

4.

Insert the 2 screws and nuts to attach the filter clamps to the bracket. See Figure 38.

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Nuvera® Fuel Cell System N1800V36/N1821V36/ N1800V48/N1824V48 Service Manual

Service procedures Drain and fill coolant

Nuvera part number

Description

Qty.

N/A

Coolant container (nonmetallic)

1

N/A

1

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

Funnel with integrated mesh strainer

N/A

3/16" hex tool

1

1.

N/A

3/8" hose

1

Scope To drain coolant from the Fuel Cell System (FCS) and replace with new.

Safety and warnings

2.

3.

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

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

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 your service provider.

WARNING The coolant may be hot. Do not remove the coolant if the radiator/heat exchanger cap is warm.

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

Care should be taken when handling coolant.

Consult MSDS for handling instructions.

Prepare

DANGER

1.

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.

Drain 1.

Parts and tools required Nuvera part number

Description

Qty.

31009749

Dynalene LCEG 50

AR

Remove the FCS from the lift truck. Confirm the FCS is powered off.

31

Locate the radiator cap and remove the cap from the radiator. See Figure 39.

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Nuvera® Fuel Cell System N1800V36/N1821V36/ N1800V48/N1824V48 Service Manual

Service procedures

4.

Open the coolant particiulate filter drain valve to remove much of the coolant from the FCS. Drain into the container.

5.

Most maintenance and repair items can be performed once fluid stops flowing through the ¼ valve.

6.

Locate the radiator drain plug at the bottom right of the radiator. See Figure 41.

Figure 39. Radiator cap 1.

RADIATOR CAP

2.

Locate the coolant particulate filter. See Figure 40.

Figure 41. Radiator drain plug

Figure 40. DI filter and coolant particulate filter 1.

3.

DI FILTER

2.

COOLANT PARTICULATE FILTER

Attach a 3/8" hose to the coolant particulate filter drain valve. Place the other end of the hose in a container for catching coolant.

32

1.

DRAIN PLUG

7.

Place a container under the radiator drain plug and remove the plug.

8.

Drain all coolant into the container.

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Nuvera® Fuel Cell System N1800V36/N1821V36/ N1800V48/N1824V48 Service Manual

Service procedures

Fill coolant 1.

Use the 3/16" hex tool to remove the bleed screw on top of the inlet manifold. See Figure 42.

2.

Remove the radiator cap, and fill the radiator up to the neck with new coolant. See Figure 42.

3.

Reinstall the bleed screw, but leave it slightly loose so additional air may escape.

4.

Use the NFCSST to cycle the coolant through the system by operating the coolant pump.

With the cap off, flow will be visible when looking into the top of the radiator and any trapped air bubble will be allowed to escape.

Monitor the loose bleed screw to ensure an excessive amount of coolant is not dripping out.

10. Reinstall the overflow bottle cap.

Figure 42. Fill coolant 1.

BLEED SCREW

2.

COOLANT OVERFLOW BOTTLE CAP

3.

RADIATOR CAP

• If flow is not present, try squeezing the green coolant hoses throughout the system to purge any air.

• If no-flow condition persists, place a bucket underneath the ¼ turn valve at the end of the coolant particulate filter. See Figure 40.

• Open the valve for 1 second to remove any air just upstream of the coolant pump.

5.

Tighten bleed screw once the flow has been identified in the radiator. This indicates that minimal air remains in the system.

6.

Continue to top off radiator with coolant until level no longer changes and bubbles have stopped appearing. Final coolant level should be filled to the bottom of the fill neck.

7.

Reinstall radiator cap. See Figure 42.

8.

Remove cap from overflow bottle.

9.

Ensure there is coolant present approximately 1 inch from bottom of the bottle. If no coolant is visible, fill up to 1 inch from the bottom of the bottle surface.

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Nuvera® Fuel Cell System N1800V36/N1821V36/ N1800V48/N1824V48 Service Manual

Service procedures Replacing the main battery

Scope To remove the 36/48V battery from the Fuel Cell System (FCS) and replace with new.

Nuvera part number

Description

Qty.

N/A

Torque wrench (Insulated 0.25" drive)

1

N/A

10 mm open end/box end wrench (Insulated)

1

N/A

13 mm open end/box end wrench (Insulated)

1

N/A

10 mm socket (Insulated 0.25" drive)

1

N/A

13 mm socket (Insulated 0.25" drive)

1

N/A

Ratcheting wrench (Insulsated 1/4" or 3/8" drive)

1

N/A

Insulated gloves

1 pair

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 your service provider.

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.

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

Parts and tools required

WARNING High power discharge potential

Nuvera part number

Description

Qty.

31009979

Battery (36/48V)

1

Lithium battery

N/A

Torx bit driver set

1

WARNING

WARNING

Arc flash potential 34

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Nuvera® Fuel Cell System N1800V36/N1821V36/ N1800V48/N1824V48 Service Manual

Service procedures

Prepare 1.

2.

Remove the FCS from the lift truck. Confirm the FCS is powered off.

2.

Use the 13 mm and 10 mm open end/box end wrench to remove the bolt retaining the positive battery bus bar. See Figure 43.

3.

Remove the battery communication connector. See Figure 44.

Remove the left hand upper side panel and left hand side panel. See Removing and installing the cover panels.

CAUTION

NOTE: The following procedure describes the process for removing the 48V battery. To remove attaching parts, see Parts Manual for more information.

The battery may weigh as much as 34 kgs (75 lbs). Take caution when lifting from the fuel cell system.

4.

Remove 1.

Use insulated gloves along with the 13 mm and 10 mm socket wrench to remove the bolt retaining the negative battery bus bar. See Figure 43.

Remove the two mounting screws and slide the battery straight out of the opening, paying attenttion to not damage any other components while removing the battery. See Figure 45.

Figure 43. Battery and bus bars 1.

BATTERY

2.

POSITIVE BATTERY BUS BAR

3.

35

NEGATIVE BATTERY BUS BAR

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Service procedures

Nuvera® Fuel Cell System N1800V36/N1821V36/ N1800V48/N1824V48 Service Manual 4.

Use a 6” extension and 9/16” socket. Place the extension directly above the contactor mounted on the battery bracket and insert until it reaches the negative stud block.

5.

Use the socket to remove the nut (item 5, Figure 46) holding the negative bus bar (item 4) to the negative stud on the electrical box shelf.

Figure 44. Communication connector

Figure 46. Disconnect main battery Figure 45. Battery mounting screws

Remove

1.

POSITIVE POWER CABLE

2.

CONTACTOR

3.

NUT NEGATIVE BUS BAR

5.

NUT

6.

SUPPORT BRACKET

7.

SCREWS

8.

MAIN BATTERY

1.

Remove the left hand side panel. See Removing and installing the cover panels.

4.

2.

Use a hex key to remove the two screws retaining the support bracket to the casting.

See, Figure 46.

6.

3.

Use the 13 mm socket to remove the nut (item 3, Figure 46) connecting the positive power cable (item 1) to the terminal on the battery contactor (item 2) and remove the power cable and ring terminal from the battery contactor.

Slide the main battery out of the side of the FCS just enough to gain access to the battery connector and disconnect the harness from the battery connector.

7.

Pull the battery out the rest of the way and remove from the FCS. DO NOT lift the battery, as there is very little clearance from the top of the battery and the electrical box shelf directly above it.

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Nuvera® Fuel Cell System N1800V36/N1821V36/ N1800V48/N1824V48 Service Manual

Service procedures

Install

8.

Insert the bolt retaining the negative battery bus bar. See Figure 43.

1.

Locate the new battery and connect the battery harness to the connector on the battery.

9.

Use the 13 mm and 10 mm socket wrench to tighten. Torque to 5 N•m (3.7 lbf ft.).

2.

Slide the battery back into the FCS.

3.

Apply Loctite® 242 to the two screws (item 7, Figure 46). Insert the two screws to retain the support bracket to the casting.

4.

Tighten the screws. Torque to 15 N-m (11.06 ft-lbs).

5.

Insert the nut (item 5, Figure 46) to retain the negative bus bar (item 4) to the negative stud on the electrical box shelf.

6.

Tighten the nut. Torque to 8 N-m (5.9 ft-lbs).

7.

Attach the positive power cable (item 1, Figure 46) and ring terminal to the battery contactor (item 2, Figure 46).

8.

Insert the nut (item 3, Figure 46) to connect the positive power cable to the terminal on the battery contactor.

9.

Tighten the nut. Torque to 10 N-m (7.4 ft-lbs).

10. Install the upper left hand upper side panel.

See Removing and installing the cover panels.

Install 1.

Locate the new 36/48 battery.

2.

Place the battery into the compartment. Slide the battery forward until it is up against the front of the enclosure.

3.

Insert the two mounting screws to retain the battery to the FCS. See Figure 45.

4.

Use the 10 mm wrench to tighten. Torque the screw to 5 N•m (3.7 lbf ft.).

5.

Connect the battery communication connector. See Figure 44.

6.

Insert the bolt retaining the positive battery bus bar. See Figure 43.

7.

Use the 13 mm socket and 13 mm open end/box end wrench to tighten. Torque to 10 N•m (7.4 lbf ft.).

37

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Nuvera® Fuel Cell System N1800V36/N1821V36/ N1800V48/N1824V48 Service Manual

Service procedures Replacing the 12V batteries

Scope To remove the two 12V Lithium-ion batteries 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 your service provider.

3.

Nuvera part number

Description

Qty.

N/A

Torque wrench

1

N/A

10 mm socket

1

N/A

10 open end/box wrench

1

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

Prepare Before removing the battery, the following procedures must be performed:

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

1.

Remove the FCS from the lift truck. Confirm the FCS is powered off.

2.

Remove the right hand upper side panel. See Removing and installing the cover panels.

Remove 1.

DANGER

Locate the bracket securing the 12V battery in place. See Figure 47.

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.

4306473

12V Lithium ion battery

2

N/A

Insulated gloves

1 pair

38

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Nuvera® Fuel Cell System N1800V36/N1821V36/ N1800V48/N1824V48 Service Manual

Service procedures

5.

Remove the battery from the FCS.

Install 1.

Locate new battery. See Storing the Lithium-ion batteries to confirm the 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%.

2.

Connect the quick-connect battery terminals to the new battery. See Figure 48.

Figure 47. Battery bracket

3.

Lower the new battery into the FCS.

2.

4.

Install the bracket to retain the 12V battery to the FCS. Insert the bolt and nut to attach the bracket. See Figure 47.

5.

Torque to 5 N•m (3.7 lbf ft.).

6.

Install the upper left hand upper side panel.

See Removing and installing the cover panels.

1.

BOLT

2.

Remove the bolt and nut retaining the bracket. See Figure 47.

3.

BRACKET

Slide the battery out far enough to access the quick-connect terminals. See Figure 48.

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 (disconnected) storage shelf-life of 12 months from date of manufacturing. The manufacturing date can be determined from the battery label.

• Locate the serial number below the barcode. See Figure 49.

• Find the four-digit portion of the serial number as indicated in Figure 49.

Figure 48. Battery terminals 1.

BATTERY TERMINALS

2.

12 V BATTERY

4.

Disconnect the quick-connect terminals from the battery.

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Nuvera® Fuel Cell System N1800V36/N1821V36/ N1800V48/N1824V48 Service Manual

Service procedures • 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 49, the four digit number is 1616. This indicates the battery was manufactured in the 16th week of 2016.

Figure 49. Battery label • If the battery has been sitting for more than 12 months, it must be recharged.

• Determine the current battery state of charge.

• 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 50.

• 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%.

40

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Service procedures

Nuvera® Fuel Cell System N1800V36/N1821V36/ N1800V48/N1824V48 Service Manual

Figure 50. Depth of discharge vs. battery cell voltage 41

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Nuvera® Fuel Cell System N1800V36/N1821V36/ N1800V48/N1824V48 Service Manual

Service procedures Replacing the DC/DC assembly

Nuvera part number

Description

Qty.

To remove the DC/DC assembly from the Fuel Cell System (FCS) and replace with new.

N/A

Voltmeter/ Multimeter (low voltage)

3

Safety and warnings

N/A

Ratcheting wrench

1

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

N/A

Torque wrench

1

N/A

10 mm socket

1

N/A

10 mm open end/box end wrench

1

N/A

3 mm hex key/bit

1

N/A

Bit driver

1

N/A

Insulated gloves

1 pair

Scope

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 your service provider.

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

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

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.

1.

Remove the FCS from the lift truck. Confirm the FCS is powered off.

2.

Remove the right hand upper side panel. See Removing and installing the cover panels.

Remove

Parts and tools required

1.

Nuvera part number

Description

Qty.

31009881

DC/DC Assembly

1

42

Locate the DC/DC assembly. See Figure 51.

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Nuvera® Fuel Cell System N1800V36/N1821V36/ N1800V48/N1824V48 Service Manual

Service procedures

3.

Use the 10 mm open end/box wrench to remove the 3 screws attaching the DC/DC bus bars to their mating bus bars. See Figure 52.

Figure 52. Attaching bus bars Figure 51. DC/DC location 1.

DC/DC ASSEMBLY

3.

POSITIVE DC/DC BUS BAR

2.

NEGATIVE DC/DC BUS BAR

2.

Use the voltmeter/multimeter to confirm there is less that 1 Vdc on the positive bus bars. See Figure 51.

1.

SCREWS

4.

Use the 10 mm open end/box wrench to remove the 4 screws attaching the DC/DC bus bars to the electrical box. Make sure the tools do not contact PCB components. See Figure 53.

• If voltage is greater than 1 Vdc, confirm that system is shut off and that batteries are disconnected.

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Nuvera® Fuel Cell System N1800V36/N1821V36/ N1800V48/N1824V48 Service Manual

Service procedures

Figure 53. DC/DC mounting bolts 1.

DC/DC ATTACHING SCREWS

5.

Disconnect the DC/DC communication connector. See Figure 54.

6.

44

Disconnect the white and black cooling fan connectors. See Figure 54.

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Nuvera® Fuel Cell System N1800V36/N1821V36/ N1800V48/N1824V48 Service Manual

Service procedures

Figure 54. DC/DC connectors 1.

DC/DC COMMUNICATION CONNECTOR

4.

SCREWS

2.

WHITE COOLING FAN CONNECTOR

5.

COOLING FANS

3.

BLACK COOLING FAN CONNECTOR

7.

Remove the DC/DC from the FCS.

7.

8.

If replacing the the cooling fans, use a hex key to remove the screws retaining the fan(s) to the DC/DC. Remove the fan(s). See Figure 54.

Use the 10 mm open end/box wrench to tighten. Torque to 5 N•m (3.7 lbf ft.).

8.

Install the right hand upper side panel. See Removing and installing the cover panels.

Install 1.

If the cooling fans were removed, install the fans onto the new DC/DC assembly and insert the mounting screws. See Figure 54.

2.

Torque to 2 N•m (1.5 lbf ft.).

3.

Install the new DC/DC into the FCS.

4.

Insert the 4 screws to attach the DC/DC bus bars to the electrical box. Make sure the tools do not contact PCB components. See Figure 53.

5.

Use the 10 mm open end/box wrench to tighten. Torque to 5 N•m (3.7 lbf ft.).

6.

Insert the 3 screws attaching the DC/DC bus bars to their mating bus bars. See Figure 52.

45

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Nuvera® Fuel Cell System N1800V36/N1821V36/ N1800V48/N1824V48 Service Manual

Service procedures Replacing the main PCB and system controller (STW)

Nuvera part number

Description

Qty.

N/A

1

To remove the main PCB and STW controller from the Fuel Cell System (FCS) and replace with new.

Torx bit set and driver

N/A

Socket set

1

Safety and warnings

N/A

Ratcheting wrench (1/4")

1

N/A

Snips for removing cable ties

1

Scope

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.

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

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 your service provider.

Prepare

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

1.

Remove the FCS from the lift truck. Confirm the FCS is powered off.

2.

Remove the front panel and right hand upper side panel. See Removing and installing the cover panels.

Remove NOTE: The following procedure describes the process for removing the STW. If removing any of the attaching parts, see the Parts Manual.

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.

Disconnect the 12V battery connector. See Replacing the 12V batteries.

2.

Locate the main connector on STW controller harness. See Figure 55.

Parts and tools required Nuvera part number

Description

Qty.

31009867

PCB board

1

4306474

STW controller

1

N/A

Hex key set

1

46

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Nuvera® Fuel Cell System N1800V36/N1821V36/ N1800V48/N1824V48 Service Manual

Service procedures

Figure 56. PCB electrical connectors Figure 55. STW harness 1.

STW HARNESS

3.

CONNECTORS AT PCB

2.

MAIN CONNECTOR

3.

Disconnect the main connector. See Figure 55.

4.

Disconnect the three STW connectors from the PCB. See Figure 55.

5.

Disconnect all remaining removable connectors from the main PCB and slide connectors out of the way. See Figure 56.

1.

CONNECTORS

6.

Remove the four screws attaching the PCB to the mounting bracket. Remove the PCB. See Figure 57.

Figure 57. PCB mounting

47

1.

SCREWS

7.

Remove the four screws attaching the STW controller to the mounting bracket. Remove the STW. See Figure 58.

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Service procedures

Nuvera® Fuel Cell System N1800V36/N1821V36/ N1800V48/N1824V48 Service Manual

Figure 58. STW mounting 1.

SCREWS

8.

Slide the STW controller out of the FCS from the front.

Install 1.

Locate the new STW controller.

2.

From the front of the FCS, slide the new STW controller into place.

3.

Insert the four screws attaching the STW controller to the mounting bracket. See Figure 58.

4.

Torque to 10 N•m (7.4 lbf ft.).

5.

Insert the four screws attaching the PCB to the mounting bracket. See Figure 57.

6.

Torque to 3 N•m (2.2 lbf ft.).

7.

Connect all connectors to the main PCB. See Figure 56.

8.

Connect the main connector. See Figure 55.

9.

Connect the 12V battery connector. See Replacing the 12V batteries.

10. Install the front panel and right hand upper side panel. See Removing and installing the cover panels.

48

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Nuvera® Fuel Cell System N1800V36/N1821V36/ N1800V48/N1824V48 Service Manual

Service procedures Replacing the data port

Scope To remove the data port from the Fuel Cell System (FCS) and replace with new.

Nuvera part number

Description

Qty.

N/A

23 mm (15/16") open end/box wrench

1

N/A

Snips for removing cable ties

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 your service provider.

3.

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

Prepare

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

1.

Remove the FCS from the lift truck. Confirm the FCS is powered off.

2.

Remove the top and right hand upper side panel. See Removing and installing the cover panels.

NOTE: The following procedure describes the process for removing the data port. If removing any of the attaching parts, see the Parts Manual.

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.

1.

Locate the data port connecter at the main PCB.

2.

Disconnect the data port connector from the main PCB. See Figure 59.

Parts and tools required Nuvera part number

Description

Qty.

N/A

Data port

1

49

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Nuvera® Fuel Cell System N1800V36/N1821V36/ N1800V48/N1824V48 Service Manual

Service procedures

Install 1.

Locate the new data port and install inside the FCS.

2.

Connect the data port connector to the main PCB. See Figure 59.

3.

Insert the data port through the hole in the front panel. Install the nut to retain the data port to the front panel and tighten. See Figure 60.

4.

Install the top panel. See Removing and installing the cover panels.

Figure 59. Data port connector 1.

DATA PORT NUT

2.

DATA PORT CONNECTOR

3.

Locate the nut retaining the data port to the front of the FCS. See Figure 60.

Figure 60. Data port nut 1.

DATA PORT NUT

4.

Use the 23 mm (15/16") wrench to loosen the data port nut from the front panel. See Figure 60.

5.

Remove the data port from inside the FCS.

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Nuvera® Fuel Cell System N1800V36/N1821V36/ N1800V48/N1824V48 Service Manual

Service procedures Replacing the start button

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

Scope

Prepare

To remove the start button from the Fuel Cell System (FCS) and replace with new.

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

1.

2.

3.

1.

Remove the FCS from the lift truck. Confirm the FCS is powered off.

2.

Remove the top panel. See Removing and installing the cover panels.

Remove

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

NOTE: The following procedure describes the process for removing the start button. If removing any of the attaching parts, see the Parts Manual.

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 your service provider.

1.

Locate the connector at the the back of the start button. Disconnect the connector from the start button. See Figure 61.

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 tools required

Figure 61. Start button nut

Nuvera part number

Description

Qty.

71001059

Start button

1

N/A

Needle nose pliers

1

51

1.

START BUTTON NUT

2.

START BUTTON CONNECTOR

2.

Locate the nut retaining the back of the start button to the inside of the front panel. See Figure 61.

3.

Use the needle nose pliers to loosen the nut. www.nuvera.com

Service procedures 4.

Nuvera® Fuel Cell System N1800V36/N1821V36/ N1800V48/N1824V48 Service Manual

Remove the start button from the front panel.

Install 1.

Locate the new start button and install it to the front panel of the FCS.

2.

Insert the nut to attach the start button to the back of the front panel and tighten. See Figure 61.

3.

Connect the start button connector to the start button. See Figure 61.

4.

Install the top panel. See Removing and installing the cover panels.

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Nuvera® Fuel Cell System N1800V36/N1821V36/ N1800V48/N1824V48 Service Manual

Service procedures Replacing the emergency stop button

Prepare

Scope

1.

To remove the emergency stop (E-stop) button from the Fuel Cell System (FCS) and replace with new.

Remove the FCS from the lift truck. Confirm the FCS is powered off.

2.

Remove the top panel. See Removing and installing the cover panels.

Remove

Safety and warnings

NOTE: The following procedure describes the process for replacing the emergency stop button.

To replace attaching parts, see the Parts Manual.

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 your service provider.

1.

Locate the E-stop button. See Figure 62.

2.

Disconnect the latch on the E-stop from the contact block. See Figure 62.

3.

Loosen the securement ring retaining the Estop button to the bracket.

4.

Remove the E-stop button through the front panel.

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 62. E-stop button

Parts and tools required Nuvera part number

Description

Qty.

71001058

E-stop button

1

1.

E-STOP BUTTON

2.

SECUREMENT RING

3.

LATCH TO CONTACT BLOCK

Install

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

53

1.

Locate the new E-stop button.

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Service procedures 2.

Insert the E-stop button through the hole in the front panel. See Figure 62.

3.

Connect the E-stop button to the contact block.

4.

Tighten the securement ring to retain the Estop button to the inside of the front panel.

See Figure 62.

5.

Install the top panel. See Removing and installing the cover panels.

Nuvera® Fuel Cell System N1800V36/N1821V36/ N1800V48/N1824V48 Service Manual

54

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Nuvera® Fuel Cell System N1800V36/N1821V36/ N1800V48/N1824V48 Service Manual

Service procedures Replacing the E-Stop contact block

Scope To replace the emergency stop contact block and replace with new.

Nuvera part number

Description

Qty.

N/A

Small flathead screwdriver (3-4 mm tip width)

1

Safety and warnings

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

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 your service provider.

3.

Prepare 1.

Remove the FCS from the lift truck. Confirm the FCS is powered off.

2.

Remove the top panel. See Removing and installing the cover panels.

Remove 1.

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

Disconnect the low voltage battery. See Disconnecting the batteries.

2.

Use the flathead screwdriver to remove the yellow and black wire from the back of the contact block. See Figure 63.

DANGER

3.

Remove the contact block from the back of the emergency stop. See Figure 63.

4.

Remove faulty contact block from FCS.

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 tools required Nuvera part number

Description

Qty.

N/A

E-stop contact block

1

55

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Nuvera® Fuel Cell System N1800V36/N1821V36/ N1800V48/N1824V48 Service Manual

Service procedures

Figure 63. E-stop contact block 1.

YELLOW WIRE CONNECTION

2.

BLACK WIRE CONNECTION

Install 1.

Locate the new contact block.

2.

Insert the new contact block into the FCS and connect to the back of the E-stop button. See Figure 63.

3.

Connect ESTP_21 (black wire) and ESTP_22 (yellow wire) to the matching numbered screw terminals on the contact block. See Figure 63.

4.

Use the flathead screwdriver to tighten the screws.

5.

Connect the low voltage battery. See Disconnecting the batteries.

6.

Install the top panel. See Removing and installing the cover panels.

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Nuvera® Fuel Cell System N1800V36/N1821V36/ N1800V48/N1824V48 Service Manual

Service procedures Replacing the power cables

Nuvera part number

Description

Qty.

N/A

Voltmeter/ multimeter (low voltage)

2

N/A

1

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

Ratcheting wrench (1/4" or 3/8" drive)

N/A

Torque wrench

1

1.

N/A

13 mm socket

1

Scope To remove the power cables from the Fuel Cell System (FCS) and replace with new.

Safety and warnings

2.

3.

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

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

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 your service provider.

Prepare

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

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.

Qty.

N/A

Insulated gloves

1

31009999

Power cable assembly

1

2.

Remove the top panel. See Removing and installing the cover panels.

Remove

Parts and tools required Description

Remove the FCS from the lift truck. Confirm the FCS is powered off.

NOTE: The following procedure describes the process for removing and replacing the power cables and strain relief bushing only. If replacing any attaching parts, see the Parts Manual for more information.

DANGER

Nuvera part number

1.

1.

Follow the power cables from outside of the FCS and locate the red and black cable terminations inside the system.

2.

Measure voltage across the positive and negative lugs. See Figure 64 and Figure 65.

• Confirm voltage is less that 1 VDC before proceeding.

• If voltage is higher thatn 1 VDC, troubleshooting of the system contactors is required before proceeding. See Diagnostic Troubleshooting Manual.

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Nuvera® Fuel Cell System N1800V36/N1821V36/ N1800V48/N1824V48 Service Manual

Service procedures 3.

Use the 13 mm socket to remove the bolt retaining the positive terminal. See Figure 64.

4.

Use the torque wrench to tighten. Torque the nut to 10 N•m (7.4 lbf ft.).

4.

Remove the bolt retaining the negative terminal. See Figure 65.

5.

5.

Remove the power cables from the FCS.

Connect the bolt to retain the positive terminal to the landing location. See Figure 64.

6.

Remove the bracket from the cable assembly.

6.

Use the torque wrench to tighten. Torque the nut to 10 N•m (7.4 lbf ft.).

Figure 64. Positive terminal 1.

POSITIVE TERMINAL BOLT

Figure 65. Negative terminal 1.

NEGATIVE TERMINAL BOLT

Install 1.

Locate the new power cables assembly.

2.

Install the bracket to the new cable assembly.

3.

Install the power cables into the FCS. Connect the bolt to retain the negative terminal to the landing location. See Figure 65.

58

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Nuvera® Fuel Cell System N1800V36/N1821V36/ N1800V48/N1824V48 Service Manual

Service procedures Replacing the hydrogen leak sensors

Scope To remove the hydrogen leak sensors (AS5 or AS6) from the Fuel Cell System (FCS) and replace with new.

Nuvera part number

Description

Qty.

N/A

Torque wrench

1

N/A

Bit driver

1

N/A

3 mm hex key/bit

1

Safety and warnings

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

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 your service provider.

3.

Prepare

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

1.

Remove the FCS from the lift truck. Confirm the FCS is powered off.

2.

Remove the front panel if replacing AS5 sensor. See Removing and installing the cover panels.

3.

Remove the top panel if replacing AS6 sensor.

See Removing and installing the cover panels.

NOTE: The following procedure describes the process for replacing the leak sensors. To replace attaching parts see the Parts Manual for more information.

DANGER

Remove AS5 sensor

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 tools required Nuvera part number

Description

Qty.

31009915

AS5/AS6 sensor

2

N/A

T25 torx bit

3

59

1.

With the front panel removed, locate the AS5 sensor. See Figure 66.

2.

Disconnect the connector from the AS5 sensor. See Figure 66.

3.

Use the 3 mm hex bit and driver to remove the mounting screw attaching the sensor. See Figure 66.

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Nuvera® Fuel Cell System N1800V36/N1821V36/ N1800V48/N1824V48 Service Manual

Service procedures

Figure 66. AS5 sensor 1.

AS5 SENSOR

Figure 67. AS6 sensor 1.

Remove AS6 sensor

AS6 SENSOR

1.

With the top panel removed, locate the AS6 sensor. See Figure 67.

Install AS6 sensor

2.

Disconnect the connector from the AS6 sensor. See Figure 67.

1.

Locate the new AS6 sensor.

2.

With the top panel still removed, install the AS6 sensor. See Figure 67.

3.

Insert the screws to attach the sensor to the FCS. See Figure 67.

4.

Use the 3 mm hex bit and driver to tighten the screws. Torque to 3 N•m (2.2 lbf ft.). See Figure 67.

5.

Connect the connector to the AS6 sensor. See Figure 67.

6.

Install the top panel. See Removing and installing the cover panels.

3.

Use the 3 mm hex bit and driver to remove the mounting screw attaching the sensor. See Figure 67.

Install AS5 sensor

60

1.

Locate the new AS5 sensor.

2.

With the front panel still removed, install the AS5 sensor. See Figure 66.

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Nuvera® Fuel Cell System N1800V36/N1821V36/ N1800V48/N1824V48 Service Manual

Service procedures 3.

Insert the screws to attach the sensor to the FCS. See Figure 66.

4.

Use the 3 mm hex bit and driver to tighten the screws. Torque to 3 N•m (2.2 lbf ft.). See Figure 66.

5.

Connect the connector to the AS5 sensor. See Figure 66.

6.

Install the top panel. See Removing and installing the cover panels.

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Nuvera® Fuel Cell System N1800V36/N1821V36/ N1800V48/N1824V48 Service Manual

Service procedures Replacing the air compressor

Nuvera part number

Description

Qty.

To remove the air compressor from the Fuel Cell System (FCS) and replace with new.

N/A

10 mm socket (swivel/U-Joint recommended)

1

Safety and warnings

N/A

Socket set

1

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

N/A

Torx bit and driver set

3

N/A

Torque wrench

1

N/A

Hex key/bit set

1

Scope

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 your service provider.

3.

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

Prepare

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

DANGER

Qty.

31009804

Air compressor

1

N/A

Ratcheting wrench

1

2.

Remove the upper right hand side panel and upper left hand side panel. See Removing and installing the cover panels.

3.

Remove the main battery. See Replacing the main battery.

Remove

Parts and tools required Description

Remove the FCS from the lift truck. Confirm the FCS is powered off.

NOTE: The following procedure describes the process for replacing the air compressor. To replace attaching parts see the Parts Manual for more information.

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.

Nuvera part number

1.

62

1.

Disconnect the compressor wire harness from the compressor motor controller (item 3, Figure 68).

2.

Disconnect the compressor wire harness from the main wire harness (item 2, Figure 68).

3.

Use the 10 mm socket to remove the two rear mounting screws retaining the compressor to the casting. See Figure 68.

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Nuvera® Fuel Cell System N1800V36/N1821V36/ N1800V48/N1824V48 Service Manual

Service procedures

7.

Use the 10 mm socket to remove the two front screws retaining the compressor to the casting. See Figure 70.

Figure 68. Compressor connectors 1.

MAIN WIRE HARNESS CONNECTIONS

2.

REAR MOUNTING SCREWS

3.

MOTOR CONTROLLER CONNECTORS.

Figure 70. Compressor front mounting screws

4.

Use the 7 mm socket to loosen the hose clamps on the compressor hoses. See Figure 69.

5.

Use the 3 mm hext bit to remove the screw from the hose routing clamp. See Figure 69.

6.

Remove the compressor hoses.

HOSE CLAMPS

2.

FRONT MOUNTING SCREWS

8.

Slide the compressor out from the front, leaving the rubber isolators in place.

Install

Figure 69. Compressor hoses 1.

1.

HOSE ROUTING CLAMP

63

1.

Locate the new air compressor.

2.

Install the compressor into the FCS.

3.

Insert the two front mounting screws to attach the compressor to the casting. See Figure 70.

4.

Torque to 6 N•m (4.4 lbf ft.).

5.

Connect the compressor hoses and tighten the hose clamps. See Figure 69.

6.

Insert the screw into the hose routing clamp.

See Figure 69.

7.

Torque to 3 N•m (2.2 lbf ft.). See Figure 68.

8.

Insert the two rear mounting screws to attach the compressor to the casting. See Figure 68.

9.

Torque to 6 N•m (4.4 lbf ft.). See Figure 68. www.nuvera.com

Service procedures

Nuvera® Fuel Cell System N1800V36/N1821V36/ N1800V48/N1824V48 Service Manual

10. Connect the connectors to the compressor motor controller. See Figure 68.

11. Install the right upper side panel and left upper side panel. See Removing and installing the cover panels.

64

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Nuvera® Fuel Cell System N1800V36/N1821V36/ N1800V48/N1824V48 Service Manual

Service procedures Replacing the air compressor motor controller

Scope To remove the air compressor motor controller from the Fuel Cell System (FCS) and replace with new.

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

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 your service provider.

3.

Description

Qty.

N/A

Torque wrench

1

N/A

Bit driver

1

N/A

3 mm hex bit

1

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

Safety and warnings

1.

Nuvera part number

Prepare 1.

Remove the FCS from the lift truck. Confirm the FCS is powered off.

2.

Remove the upper left hand side panel. See Removing and installing the cover panels.

3.

Remove the main battery. See Replacing the main battery.

NOTE: The following procedure describes the process for replacing the air compressor motor controller. To replace attaching parts see the Parts Manual for more information.

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

Remove 1.

Disconnect the compressor wire harness from the compressor motor controller at the spade terminals. Figure 71.

2.

Disconnect the connectors from the communication ports on the compressor motor controller. See 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.

Parts and tools required Nuvera part number

Description

Qty.

31009937

Air compressor motor controller

1

65

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Nuvera® Fuel Cell System N1800V36/N1821V36/ N1800V48/N1824V48 Service Manual

Service procedures

Figure 71. Compressor motor controller connectors 1.

SPADE TERMINALS

2.

CONNECTORS TO COMMUNICATION PORTS

3.

Use the 3 mm hext bit to remove the four screws retaining the motor controller. See Figure 72.

4.

Remove the harness bracket and controller.

See Figure 72.

Figure 72. Compressor mounting 1.

SCREWS

2.

HARNESS BRACKET

3.

CONTROLLER

Install

66

1.

Locate the new compressor motor controller.

2.

Align the controller and harness bracket in position in the FCS.

3.

Insert the four screws to attach the controller to the FCS. See Figure 72.

4.

Torque to 3 N•m (2.2 lbf ft.).

5.

Connect the connectors to the communication ports. See Figure 71.

6.

Connect the connectors to the compressor motor controller. See Figure 73.

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Service procedures

Nuvera® Fuel Cell System N1800V36/N1821V36/ N1800V48/N1824V48 Service Manual

Figure 73. Terminal connections 7.

Install the left upper side panel. See Removing and installing the cover panels.

67

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Nuvera® Fuel Cell System N1800V36/N1821V36/ N1800V48/N1824V48 Service Manual

Service procedures Replacing the coolant pump

Nuvera part number

Description

Qty.

To remove the coolant pump from the Fuel Cell System (FCS) and replace with new.

N/A

Ratcheting wrench (1/4” or 3/8” Drive)

1

Safety and warnings

N/A

Torque wrench

1

Scope

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

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.

Parts and tools 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 your service provider.

Nuvera part number

Description

Qty.

N/A

Coolant pump

1

N/A

Torx bit and driver set

1

N/A

Socket set

1

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

N/A

Ratcheting wrench (1/4” or 3/8” Drive)

1

N/A

Torque wrench

1

DANGER

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

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.

Prepare 1.

Remove the FCS from the lift truck. Confirm the FCS is powered off.

2.

Remove the upper left hand side panel, upper right hand side panel and rear panel. See Removing and installing the cover panels.

3.

Drain the coolant from the system. See Drain and fill coolant.

Parts and tools required Nuvera part number

Description

Qty.

31009817

Coolant pump

1

N/A

Torx bit and driver set

1

N/A

Socket set

1

68

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Nuvera® Fuel Cell System N1800V36/N1821V36/ N1800V48/N1824V48 Service Manual

Service procedures NOTE: The following procedure describes the process for replacing the coolant pump. To replace attaching parts see the Parts Manual for more information.

Remove 1.

Disconnect the two harness connections to the pump. See Figure 74.

Figure 75. Coolant hoses 1.

HOSE CLAMPS

3.

COOLANT HOSES

2.

MOUNTING SCREWS

4.

COOLANT PUMP MOUNTING BRACKET

Install

Figure 74. Coolant pump and connections 1.

COOLANT PUMP

2.

Locate the new coolant pump.

2.

Install the coolant pump into the mounting bracket. See Figure 75.

3.

Insert the four screws to attach the coolant pump to the mounting bracket. See Figure 75.

4.

Torque to 25N•m (18.4 lbf ft.).

5.

Connect the coolant hoses to the pump. See Figure 75.

6.

Install the hose clamps and tighten. Torque to 3 N•m (2.2 lbf ft.).

7.

Connect the harness connections to the pump. See Figure 74.

8.

Install all removed panels. See Removing and installing the cover panels.

CONNECTORS

2.

Use the 7 mm socket to remove the hose clamps from each coolant hose. See Figure 75.

3.

Remove the hoses from the coolant pump.

See Figure 75.

4.

Use the 13 mm socket to remove the mounting screws retaining the coolant pump to the mounting bracket. See Figure 75.

5.

1.

Remove the coolant pump. See Figure 75.

69

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Nuvera® Fuel Cell System N1800V36/N1821V36/ N1800V48/N1824V48 Service Manual

Service procedures Replacing the coolant filter/manifold

Nuvera part number

Description

Qty.

To remove the coolant filter/manifold from the Fuel Cell System (FCS) and replace with new.

N/A

Ratcheting wrench (1/4” or 3/8” Drive)

1

Safety and warnings

N/A

Torque wrench

1

N/A

Socket set

1

N/A

Hex bit set and driver

1

Scope

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.

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

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 your service provider.

Prepare

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

DANGER

Qty.

N/A

Coolant filter/ manifold

1

2.

Remove the top and right hand upper side panels. See Removing and installing the cover panels.

3.

Disconnect the main battery. See Disconnecting the batteries.

4.

Drain all coolant from the sensor. See Drain and fill coolant.

Remove

Parts and tools required Description

Remove the FCS from the lift truck. Confirm the FCS is powered off.

NOTE: The following procedure describes the process for replacing the coolant filter/manifold.

To replace attaching parts see the Parts Manual for more information.

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.

Nuvera part number

1.

70

1.

Remove the five screws at the bottom of the radiator bracket to allow the radiator and bracket to lean away from the FCS. See Figure 76.

2.

Use the 7 mm socket to remove the hose clamps and hoses on both ends of the filter/ manifold assembly. See Figure 77.

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Nuvera® Fuel Cell System N1800V36/N1821V36/ N1800V48/N1824V48 Service Manual

Service procedures

Figure 77. Filter/manifold hoses 1.

HOSE CLAMPS

4.

TUBE

2.

SENSOR CONNECTORS

5.

TUBE CLAMP

3.

SCREWS

Figure 76. Bracket and screws 1.

SCREW

4.

BOTTOM MOUNTS

2.

RADIATOR BRACKET

5.

TOP MOUNTS

3.

CONNECTORS TO COMMUNICATION PORTS

3.

Use the 7 mm socket to remove the hose clamps and hoses on both ends of the filter/ manifold assembly. See Figure 77.

4.

Remove the tube clamp and tube running to the DI Filter. See Figure 77.

5.

Remove the electrical connectors from the tops of the sensors. See Figure 77.

6.

Use the 10 mm socket and extension to remove the two screws retaining the filter/ manifold. See Figure 77.

7.

Slide the filter/manifold out the side of the FCS.

Remove the particulate filter Once the filter/manifold assemmby has been removed, the particualte filter can be removed from the assembly.

71

1.

Remove the three NPT connections from the particulate filter. See Figure 78.

2.

Remove the particulate filter. See Figure 78.

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Service procedures

Nuvera® Fuel Cell System N1800V36/N1821V36/ N1800V48/N1824V48 Service Manual

Figure 78. Coolant particulate filter

Install the particulate filter 1.

Locate the new particulate filter.

2.

Apply 10 full wraps of sealing tape to the threaded portions of the three NPT connections. See Figure 78.

3.

Ensure all components are aligned as shown in Figure 79, and install each of the NPT connection fittings into the particulate filter.

Figure 79. Filter orientation

Install

NOTE: If the connection is tightened out of alignment, do not attempt to loosen the fitting to align it in the correct position. This could cause the connection to leak. Remove the component and install fresh sealing tape on the fitting then attempt to install the fitting again.

4.

Attach the particulate filter back to the manifold.

72

1.

Locate the new filter/manifold and install into the FCS.

2.

Insert the two screws to retain the filter/ manifold. See Figure 77. Torque to 3 N•m (2.2 lbf ft.).

3.

Connect the electrical connectors to the tops of the sensors. See Figure 77.

4.

Install the tube running to the DI Filter and tighten the tube clamp. See Figure 77.

5.

Connect the hoses to both ends of the filter/ manifold assembly and tighten the hose clamps.

6.

Insert the five screws at the bottom of the radiator bracket to attach the radiator bracket. See Figure 76. Torque to 25 N•m (18.4 lbf ft.).

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Service procedures 7.

Nuvera® Fuel Cell System N1800V36/N1821V36/ N1800V48/N1824V48 Service Manual

Install the left hand upper side panel. See Removing and installing the cover panels.

73

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Nuvera® Fuel Cell System N1800V36/N1821V36/ N1800V48/N1824V48 Service Manual

Service procedures Replacing the radiator

Scope To remove the radiator from the Fuel Cell System (FCS) and replace with new.

Nuvera part number

Description

Qty.

N/A

Hex key/bit set

1

N/A

Ratcheting wrench (1/4" or 3/8" drive)

1

N/A

Torque wrench 25 N-m

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.

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

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 your service provider.

Prepare

3.

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

DANGER

1.

Remove the FCS from the lift truck. Confirm the FCS is powered off.

2.

Remove the right hand upper side panel and left hand upper side panel. See Removing and installing the cover panels.

3.

Remove the top panel and front panel. See Removing and installing the cover panels.

4.

Drain all coolant from the system. See Drain and fill coolant.

NOTE: The following procedure describes the process for removing the radiator. If removing any of the attaching parts, see the Parts Manual.

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 1.

Use a socket to remove the hose clamps on the four hoses (two coolant, two air/cathode) attached to the radiator module. See Figure 80.

2.

Remove the hoses. See Figure 80.

Parts and tools required Nuvera part number

Description

Qty.

31009922

Radiator

1

N/A

Torx bit set and bit driver

1

N/A

Socket set

1

74

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Nuvera® Fuel Cell System N1800V36/N1821V36/ N1800V48/N1824V48 Service Manual

Service procedures

Figure 80. Radiator and hoses 1.

HOSE CLAMPS

5.

FAN CONNECTOR

2.

CATHODE HOSE

6.

CATHODE HOSE

3.

COOLING HOSE

7.

BOLT

4.

COOLING HOSE

3.

Disconnect the radiator fan connector. See Figure 80.

4.

Disconnect the two TMAP sensor connectors along the backside of the radiator. See Figure 81.

5.

Cut cable ties as necessary to free harness from module.

6.

Use the 3mm hex bit/key to remove the two M4 screws attaching the fan connector bracket to the lift bracket. See Figure 81.

7.

Use the 5mm hex bit/key to remove the flat head screws attaching the lift bracket to the casting. See Figure 81.

Figure 81. Radiator connectors 1.

M8 SCREWS

4.

LOWER ISOLATORS

2.

M4 SCREWS

5.

UPPER ISOLATORS

3.

TMAP CONNECTORS

8.

Slide the lift bracket up and out of the rubber isolators on the top of the radiator. See Figure 81.

9.

Lift the radiator up and out of the lower rubber isolators. See Figure 81. Some pivoting is required around the coolant pump area to free the radiator from the stack shelf bracket (due to the welded elbows on radiator module).

10. Place the the radiator on a workbench.

11. If replacing the radiator fan, use the 10mm socket to remove the four bolts retaining the fan to the radiator (item 7, Figure 80). Ensure radiator fan connector is facing up when installing new fan.

Clean 1.

75

The radiator may be cleaned with mild soap and water to remove any dust buildup. www.nuvera.com

Nuvera® Fuel Cell System N1800V36/N1821V36/ N1800V48/N1824V48 Service Manual

Service procedures 2.

Make sure all hose ports are capped before rinsing or washing the radiator with water.

3.

After washing, make sure the radiator is completely dry before installing fan.

Install 1.

Align the fan with the new radiator, making sure the fan connector is facing up.

2.

Insert the four bolts to attach the fan to the radiator. See Figure 80. Torque to 5 N•m (3.7 lbf ft.).

3.

Place the lower isolators onto the the radiator pins and lower the radiator into the FCS. See Figure 81. Some pivoting is required around the coolant pump area to work the radiator around the stack shelf bracket (due to the welded elbows on radiator module).

4.

Install the bracket onto the rubber isolators on the top of the radiator. See Figure 81.

5.

Insert the M8 screws to attach the lift bracket to the casting. See Figure 81. Torque to 25 N•m (18.4 lbf ft.).

6.

Insert the two M4 screws to attach the fan connector bracket to the lift bracket. See Figure 81. Torque to 3 N•m (2.2 lbf ft.).

7.

Connect the radiator fan connector. See Figure 80.

8.

Connect the two TMAP sensor connectors to the backside of the radiator. See Figure 81.

9.

Install the hoses and hose clamps. See Figure 80.

10. Torque to 3 N•m (2.2 lbf ft.).

11. Install the right hand upper side panel and left hand upper side panel. See Removing and installing the cover panels.

12. Install the top panel and front panel. See Removing and installing the cover panels.

76

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Nuvera® Fuel Cell System N1800V36/N1821V36/ N1800V48/N1824V48 Service Manual

Service procedures Replacing the fuel cell stack

Nuvera part number

Description

Qty.

To remove the fuel cell stack from the Fuel Cell System (FCS) and replace with new.

N/A

Voltmeter/ multimeter

1

N/A

Torx bit set

1

Safety and warnings

N/A

Hex bit/key set

1

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

N/A

Bit driver

1

N/A

Socket set

1

N/A

Ratcheting wrench

1

N/A

Torque wrench

1

Scope

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 your service provider.

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

Prepare 1.

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

Remove the FCS from the lift truck. Confirm the FCS is powered off.

2.

Remove the left hand upper side panel, right hand upper side panel and top panel. See Removing and installing the cover panels.

DANGER

3.

Drain all coolant from the system. See Drain and fill coolant.

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: The following procedure describes the process for replacing the fuel cell stack and fuel cell stack gasket. To replace any attaching parts, see the Parts Manual for more information.

Remove

Parts and tools required Nuvera part number

Description

Qty.

31009943

Fuel cell stack

1

N/A

Insulated gloves

1

77

1.

Use the multimeter to confirm there is less than 1 Vdc between the stack and the positve bus bar. See Figure 82.

2.

Use the multimeter to confirm there is less than 1 Vdc between the stack and the negative bus bar. See Figure 83.

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Nuvera® Fuel Cell System N1800V36/N1821V36/ N1800V48/N1824V48 Service Manual

Service procedures • If voltage greater than 1 Vdc is present, confirm the system is powered off that batteries are disconnected. See Disconnecting the batteries.

Figure 83. Negative bus bar

Figure 82. Positive bus bar 1.

FUEL CELL STACK

2.

1.

FUEL CELL STACK

3.

Use the 10 mm socket and 4 mm hex bit to remove the positive bus bar. See Figure 82.

4.

Remove the screws from the stack side of the negative busbar. Do not completely remove busbar from unit. See Figure 83.

5.

Locate the three hose connections on right side of the fuel cell stack. See Figure 84.

POSITIVE BUS BAR

78

2.

NEGATIVE BUS BAR

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Nuvera® Fuel Cell System N1800V36/N1821V36/ N1800V48/N1824V48 Service Manual

Service procedures

Figure 84. Stack hoses right side 1.

COOLANT HOSE

2.

3.

Figure 85. Stack hoses left side

HYDROGEN HOSE

1.

COOLANT HOSE

3.

HYDROGEN HOSE

AIR HOSE

2.

AIR HOSE

6.

Use the 7 mm socket to remove the hose clamps retaining each hose. Remove each hose from the ports on the stack. See Figure 84.

8.

Use the 7 mm socket to remove the hose clamps retaining each hose. Remove each hose from the ports on the stack. See Figure 84.

7.

Locate the three hose connections on left side of the fuel cell stack. See Figure 85.

9.

Remove all electrical connectors from the sensors on the stack manifolds.

10. Use the 3 mm hex bit/key to remove the four screws retainting the bottom of the stack to the mounting bracket. See Figure 86.

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Nuvera® Fuel Cell System N1800V36/N1821V36/ N1800V48/N1824V48 Service Manual

Service procedures

12. Lift the stack up off the mounting bracket and out of the FCS. Pay close attention to not damage the hydrogen fittings located at the bottom of each stack manifold. See Figure 88.

Figure 86. Fuel cell stack bottom mounting 1.

FUEL CELL STACK

2.

MOUNTING BRACKET

3.

Figure 88. Stack inlet and outlet fittings

SCREWS

1.

Figure 87. Fuel cell stack side mounting FUEL CELL STACK

2.

MOUNTING BRACKET

3.

2.

OUTLET FITTING

Install

11. Use the 2.5 mm hex bit/key to remove the eight screws retainting the side of the stack to the mounting bracket. See Figure 87.

1.

INLET FITTING

1.

Locate the new fuel cell stack.

2.

Lower the new stack onto the mounting bracket. Pay close attention to not damage the hydrogen fittings located at the bottom of each stack manifold. See Figure 88.

3.

Insert the eight screws retainting the side of the stack to the mounting bracket. See Figure 87. Torque to 3 N•m (2.2 lbf ft.).

4.

Insert the four screws retainting the bottom of the stack to the mounting bracket. See Figure 86. Torque to 3 N•m (2.2 lbf ft.).

5.

Connect all electrical connectors to the sensors on the stack manifolds.

6.

Connect each hose and hose clamp to the ports on the stack. See Figure 84. Tighten the hose clamps. Torque to 3 N•m (2.2 lbf ft.).

7.

Insert the screws to attach the negative busbar. See Figure 83. Torque to 6 N•m (4.4 lbf ft.).

8.

Insert the screws to attach the positive bus bar. See Figure 82. Torque to 6 N•m (4.4 lbf ft.).

SCREWS

80

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Service procedures 9.

Nuvera® Fuel Cell System N1800V36/N1821V36/ N1800V48/N1824V48 Service Manual

Fill the system with coolant. See Drain and fill coolant.

10. Install the left hand upper side panel, right hand upper side panel and top panel. See Removing and installing the cover panels.

81

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Nuvera® Fuel Cell System N1800V36/N1821V36/ N1800V48/N1824V48 Service Manual

Service procedures Replacing the truck contactor

Nuvera part number

Description

Qty.

To remove the truck contactor from the Fuel Cell System and replace with new.

N/A

Ratcheting wrench (1/4” or 3/8” Drive)

1

Safety and warnings

N/A

Torque wrench

1

N/A

13 mm socket

1 ea.

N/A

Bit driver

1

N/A

3 mm hex bit/key

1

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 your service provider.

3.

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

Prepare

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

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.

Qty.

31009911

Truck contactor

1

N/A

Flathead screwdriver

1

2.

Remove the top panel. See Removing and installing the cover panels.

Remove

Parts and tools required Description

Remove the FCS from the lift truck. Confirm the FCS is powered off.

NOTE: The following procedure describes the process for replacing the truck contactor. To replace attaching parts see the Parts Manual for more information.

DANGER

Nuvera part number

1.

82

1.

Remove the main battery bus bars. See Disconnecting the batteries.

2.

Disconnect the two harness connectors (item 1, Figure 89) to gain access to the truck fuse.

3.

Use the 13 mm socket to remove the two screws retaining the truck fuse (item 5, Figure 89).

4.

Remove the busbar from the contactor (item 2, Figure 89).

5.

Remove the positive cable busbar to the contactor (item 6, Figure 89). Move the cable out of the way. www.nuvera.com

Nuvera® Fuel Cell System N1800V36/N1821V36/ N1800V48/N1824V48 Service Manual

Service procedures 6.

7.

Use the 3 mm hex key/bit to remove the two screws securing the contactor to the bracket (item 4, Figure 89).

Disconnect the connector (item 3, Figure 89) from its base with a flathead screwdriver.

7.

Connect the contactor connector (item 3, Figure 89).

8.

Connect the main battery bus bars. See Disconnecting the batteries.

9.

Install the top panel. See Removing and installing the cover panels.

Figure 89. Truck contactor 1.

HARNESS CONNECTORS

2.

BUS BAR

3.

CONTACTOR CONNECTOR

4.

M5 SCREWS

5.

M8 SCREWS

6.

POSITIVE CABLE BUS BAR

Install 1.

Install the contactor in place on the bracket.

2.

Insert the two screws (item 4, Figure 89) to retain the contactor to the bracket. Torque to 5 N•m (6.8 lbf ft.).

3.

Connect the positive cable bus bar to the contactor (item 6, Figure 89).

4.

Connect the bus bar to the contactor (item 2, Figure 89).

5.

Insert the two screws to secure the truck fuse (item 5, Figure 89).

6.

Connect the two harnesses connectors. (item 1, Figure 89).

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Nuvera® Fuel Cell System N1800V36/N1821V36/ N1800V48/N1824V48 Service Manual

Service procedures Replacing the battery contactor

Nuvera part number

Description

Qty.

To remove the battery contactor from the Fuel Cell System and replace with new.

N/A

Ratcheting wrench (1/4” or 3/8” Drive)

1

Safety and warnings

N/A

Torque wrench

1

N/A

Socket set

1

N/A

Hex key/bit set and bit driver

1

Scope

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.

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

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 your service provider.

Prepare

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

1.

Remove the FCS from the lift truck. Confirm the FCS is powered off.

2.

Remove the top panel. See Removing and installing the cover panels.

NOTE: The following procedure describes the process for replacing the battery contactor. To replace attaching parts see the Parts Manual for more information.

DANGER

Remove

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 tools required Nuvera part number

Description

Qty.

31009831

Battery contactor

1

N/A

Flathead screwdriver

1

84

1.

Remove the main battery bus bars. See Disconnecting the batteries.

2.

Use the 13 mm socket to remove the nut (item 1, Figure 90) retaining the other bus bar to the contactor.

3.

Disconnect the connector (item 2, Figure 90) and remove from its base with a flathead screwdriver.

4.

Use the 3 mm hex key/bit to remove the two screws securing the contactor to the bracket (item 3, Figure 90).

5.

Slide the contactor forward (toward the battery) and remove from the FCS. www.nuvera.com

Nuvera® Fuel Cell System N1800V36/N1821V36/ N1800V48/N1824V48 Service Manual

Service procedures

Figure 90. Battery contactor 1.

NUT

3.

M5 SCREWS

2.

CONTACTOR CONNECTOR

4.

BATTERY CONTACTOR

Install 1.

Locate the new battery contactor and install into the FCS.

2.

Insert the two screws (item 3, Figure 90) to retain the contactor to the bracket. Torque to 5 N•m (6.8 lbf ft.).

3.

Connect the bus bar to the contactor and install the retaining nut (item 2, Figure 90).

4.

Torque to 10 N•m (13.6 lbf ft.)

5.

Connect the contactor connector (item 2, Figure 90).

6.

Connect the main battery bus bars. See Disconnecting the batteries.

7.

Install the top panel. See Removing and installing the cover panels.

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Nuvera® Fuel Cell System N1800V36/N1821V36/ N1800V48/N1824V48 Service Manual

Service procedures Replacing the DC/DC contactor

Nuvera part number

Description

Qty.

To remove the DC/DC contactor from the Fuel Cell System and replace with new.

N/A

Ratcheting wrench (1/4” or 3/8” Drive)

1

Safety and warnings

N/A

Torque wrench

1

N/A

Socket set

1

N/A

Hex bit/key set and bit driver

1

Scope

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.

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

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 your service provider.

Prepare

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

1.

Remove the FCS from the lift truck. Confirm the FCS is powered off.

2.

Remove the top panel. See Removing and installing the cover panels.

NOTE: The following procedure describes the process for replacing the DC/DC contactor. To replace attaching parts see the Parts Manual for more information.

DANGER

Remove

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 tools required Nuvera part number

Description

Qty.

31009830

DC/DC contactor

1

N/A

Flathead screwdriver

1

86

1.

Remove the main battery bus bars. See Disconnecting the batteries.

2.

Remove the battery contactor. See Replacing the battery contactor.

3.

Use the 10 mm socket to remove the screw (item 3, Figure 92) connecting the two bus bars near the current transducer.

4.

Use the 3 mm hex key/bit to remove the two screws (item 2, Figure 92) securing the current transducer bracket to the main battery bracket.

5.

Slide the current transducer and bracket out of the way. www.nuvera.com

Nuvera® Fuel Cell System N1800V36/N1821V36/ N1800V48/N1824V48 Service Manual

Service procedures 6.

Use the 13 mm socket to remove the two nuts (item 1, Figure 92) securing the bus bars to the contactor.

7.

Use the 7 mm socket to remove the two nuts (item 4, Figure 92) securing the harness terminal to the bus bars.

8.

Remove the current transducer assembly.

9.

Remove the screw (item 1, Figure 91) connecting the two back bus bars together.

10. Disconnect the DC/DC contactor connector (item 2, Figure 91) and remove it from its base with a flathead screwdriver.

Figure 92. DC/DC contactor and bus bars

11. Use the 3 mm hex key/bit to remove the two screws (item 3, Figure 91) attaching the DC/DC contactor. Remove the DC/DC contactor from the FCS.

1.

M8 NUTS

3.

BUS BAR SCREWS

2.

BRACKET SCREWS

4.

M4 NUTS

Install 1.

Install the contactor in place on the bracket.

2.

Install the rear bus bar.

3.

Install the current transducer assembly.

4.

Install the two nuts (item 4, ) securing the harness terminals to the bus bars. Torque to 4 N•m (3.0 lbf ft.).

5.

Insert the two nuts (item 1, ) securing the bus bars to the contactor. Torque to 10 N•m (7.4 lbf ft.).

6.

Align the current transducer and bracket.

7.

Insert the two screws (item 2, ) to secure the current transducer bracket to the main battery bracket. Torque to 4 N•m (3.0 lbf ft.).

8.

Insert the screw (item 3, ) to attach the two bus bars. Torque to 6 N•m (4.4 lbf ft.).

9.

Connect the main battery bus bars. See Disconnecting the batteries.

Figure 91. DC/DC contactor mounting 1.

M6 SCREW

3.

MOUNTING SCREWS

2.

DC/DC CONTACTOR CONNECTOR

4.

BATTERY CONTACTOR CONNECTOR

10. Install the top panel. See Removing and installing the cover panels.

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Nuvera® Fuel Cell System N1800V36/N1821V36/ N1800V48/N1824V48 Service Manual

Service procedures Replacing the current transducer

Nuvera part number

Description

Qty.

To remove the current transducer from the Fuel Cell System and replace with new.

N/A

Ratcheting wrench (1/4” or 3/8” Drive)

1

Safety and warnings

N/A

Torque wrench

1

N/A

Socket set

1

N/A

Hex bit/key set and bit driver

1

Scope

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.

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

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 your service provider.

Prepare

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

1.

Remove the FCS from the lift truck. Confirm the FCS is powered off.

2.

Remove the left hand upper side panel. See Removing and installing the cover panels.

NOTE: The following procedure describes the process for replacing the current transducer. To replace attaching parts see the Parts Manual for more information.

DANGER

Remove

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 tools required Nuvera part number

Description

Qty.

71001140

Current transducer

1

88

1.

Remove the positive and negative main battery bus bars. See Disconnecting the batteries.

2.

Disconnect the wire harness from the current transducer connector. See Figure 93.

3.

Remove the M4 locknuts retaining the terminals to the busbar. See Figure 93.

4.

Remove the two M8 nuts securing the busbar to the contactors. See Figure 93.

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Nuvera® Fuel Cell System N1800V36/N1821V36/ N1800V48/N1824V48 Service Manual

Service procedures

Figure 94. Current transducer subassembly 1.

Figure 93. Current transducer mounting

1.

3.

M4 BRACKET SCREWS

SUBASSEMBLY BRACKET

CURRENT TRANSDUCER

2.

M6 SCREWS

4.

BUSBAR

2.

M6 BUSBAR SCREW

3.

CURRENT TRANSDUCER CONNECTOR

4.

M4 LOCKNUTS

5.

BUSBAR

6.

M8 NUTS

5.

Remove the M6 screw attaching the busbar at the top connection point (item 2, Figure 93).

6.

Remove the two M4 screws (item 1, Figure 93) that attach the current transducer subassembly bracket.

7.

Slide the busbar subassembly out to remove from the FCS. See Figure 94.

8.

Slide the busbar out from the middle of the current transducer. See Figure 94.

9.

Remove the two M6 screws retaining the current transducer to the subassembly bracket. See Figure 94.

Install

10. Remove the current transducer from the FCS.

89

1.

Locate the current transducer. Insert the two M6 screws to attach the current transducer to the subassembly bracket. See Figure 94.

Torque to 3 N•m (2.2 lbf ft.).

2.

Install the busbar into the current transducer.

See Figure 94.

3.

Align the current transducer subassembly bracket in place. See Figure 94.

4.

Insert the two M4 screws to secure the current transducer subassembly bracket. See Figure 94. Torque to 3 N•m (2.2 lbf ft.).

5.

Insert the M6 screw to attach the busbar at the top connection point. See Figure 93.

Torque to 10 N•m (13.6 lbf ft.).

6.

Install the two M8 nuts to secure the busbar to the contactors. See Figure 93. Torque to 10 N•m (13.6 lbf ft.).

7.

Install the M4 locknuts to retain the terminals to the busbar. Torque to 3 N•m (2.2 lbf ft.).

8.

Connect the wire harness to the current transducer connector. See Figure 93. www.nuvera.com

Service procedures 9.

Nuvera® Fuel Cell System N1800V36/N1821V36/ N1800V48/N1824V48 Service Manual

Connect the main battery bus bars. See Disconnecting the batteries.

10. Install the left hand upper side panel. See Removing and installing the cover panels.

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Service procedures

Nuvera® Fuel Cell System N1800V36/N1821V36/ N1800V48/N1824V48 Service Manual

Replacing the fuses

2.

Scope

Remove the top panel, left hand upper side panel and right hand upper side panel. See Removing and installing the cover panels.

To locate the fuses and replace with new.

Remove/Install

Safety and warnings

1.

There are four main fuse areas in the fuel cell system. See Figure 95 and Figure 96.

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

2.

If removing one of the 5, 15, 20 or 25 amp fuses in the electrical box:

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 your service provider.

3.

• Disconnect the low voltage battery. See Disconnecting the batteries.

• Locate the fuse to replace. See Figure 95.

• Remove the fuse and replace.

If removing one of the 30, 40 and 450 amp fuses outside the electrical box: • Disconnect the main battery. See Disconnecting the batteries.

• Locate the fuse to replace. See Figure 96.

• Remove the fuse and replace. If removing the 450 amp fuse (item 1, Figure 96) the two retaining screws must be removed first.

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.

Prepare 1.

3.

Locate the replacement fuse. See Table 1 for reference.

4.

Install the new fuse. If installing the 450 amp fuse, insert the two retaining screws and tighten. Torque to 10 N•m (13.6 lbf ft.).

5.

Install the top panel, left hand upper side panel and right hand upper side panel. See Removing and installing the cover panels.

Remove the FCS from the lift truck. Confirm the FCS is powered off.

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Service procedures

Nuvera® Fuel Cell System N1800V36/N1821V36/ N1800V48/N1824V48 Service Manual

Figure 95. Electrical box fuses

92

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Nuvera® Fuel Cell System N1800V36/N1821V36/ N1800V48/N1824V48 Service Manual

Service procedures

Figure 96. Other fuses Table 1. System fuses Fuse rating (A)

Part number

5

71001179

15

31009880

20

31009879

25

31009878

30

31009955

40

31009956

450

31009912

93

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Nuvera® Fuel Cell System N1800V36/N1821V36/ N1800V48/N1824V48 Service Manual

Service procedures Replacing the humidifier

Scope To remove the humidifier from the Fuel Cell System and replace with new.

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

1.

2.

3.

Nuvera part number

Description

Qty.

N/A

Torque wrench

1

N/A

Socket set

1

N/A

Hex key/bit set and driver

1

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

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

Prepare

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 your service provider.

1.

Remove the FCS from the lift truck. Confirm the FCS is powered off.

2.

Remove the left hand upper side panel and top panel. See Removing and installing the cover panels.

3.

Remove the main battery. See Replacing the main battery.

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

NOTE: The following procedure describes the process for replacing the DCDC contactor. To replace attaching parts see the Parts Manual for more information.

DANGER

Remove

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.

Locate the four hoses attached to the humidifier. See Figure 97.

2.

Use the 7 mm socket to loosen the hose clamps at the ends of all hoses. See Figure 97.

Parts and tools required Nuvera part number

Description

Qty.

31009972

Humidifier

1

N/A

Ratcheting wrench (1/4” or 3/8” Drive)

1

94

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Nuvera® Fuel Cell System N1800V36/N1821V36/ N1800V48/N1824V48 Service Manual

Service procedures

Figure 97. Humidifier hose clamps 1.

HOSE CLAMPS

3.

Remove the four screws retaining the humidifier brackets to the stack shelf. See Figure 98.

4.

Remove the hoses from their fittings. See Figure 97.

5.

Remove the humidifier assembly and place on a work bench.

6.

Use the 7 mm socket to remove the four hose clamps from the humidifier ports, paying close attention to the orientation of the clamps before the removal. See Figure 99.

7.

Remove the hoses from the humidifier. See Figure 99.

8.

Use the item 1.5 mm hex key/bit to remove the eight screws retaining the two mounting brackets to the top of the humidifier. See Figure 99.

Figure 98. Humidifier mounting 1.

HUMIDIFIER BRACKET

2.

SCREW

95

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Nuvera® Fuel Cell System N1800V36/N1821V36/ N1800V48/N1824V48 Service Manual

Service procedures

Figure 99. Humidifier and hoses 1.

SCREWS

4.

HOSE CLAMPS

2.

HUMIDIFIER

5.

HOSES

3.

BRACKETS

7.

Insert the four screws to retain the humidifier brackets to the stack shelf. See Figure 98.

Torque to 1.5-2.5 N•m (1.1-1.8 lbf ft.).

8.

Install the main battery. See Replacing the main battery.

9.

Install the left hand upper side panel and top panel. See Removing and installing the cover panels.

Install 1.

Locate the new humidifier.

2.

Attach the mounting brackets and insert the eight screws to attach the brackets to the new humidifier.

3.

Torque to 3 N•m (2.2 lbf ft.)

4.

Connect the hoses and hose clamps to the humidifier. See Figure 99. Torque to 3 N•m (2.2 lbf ft.).

5.

Install the humidifier and hoses into the FCS. Attach the hoses to the fittings.

6.

Tighten the hose clamps. Torque to 3 N•m (2.2 lbf ft.).

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Nuvera® Fuel Cell System N1800V36/N1821V36/ N1800V48/N1824V48 Service Manual

Service procedures Replacing the hydrogen fill line

Scope To remove the hydrogen fill line from the Fuel Cell System and replace with new.

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 your service provider.

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

Nuvera part number

Description

Qty.

N/A

7/8" Open End / Swagelok Wrench

1

N/A

11/16” Open End / Swagelok Wrench

1

N/A

Bit driver

1

N/A

3 mm, 4 mm, 5 mm hex bit/key

1 ea.

31004846

Electronic combustible gas detector

1

31010176

or liquid leak detector (Snoop™)

1

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

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.

Parts and tools required Nuvera part number

Description

Qty.

N/A

Hydrogen fill line

1

N/A

Torque wrench

1

1.

Remove the FCS from the lift truck. Confirm the FCS is powered off.

2.

Remove the front panel and top panel. See Removing and installing the cover panels.

3.

Remove the pressure from the system. See H2 pressure relief.

NOTE: The following procedure describes the process for replacing the hydrogen fill line. To replace attaching parts see the Parts Manual for more information.

Remove 1.

97

Locate the check valve. See Figure 100.

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Nuvera® Fuel Cell System N1800V36/N1821V36/ N1800V48/N1824V48 Service Manual

Service procedures 2.

Use the 7/8' wrench to hold the check valve stationary while using the 11/16" wrench to slowly loosen the nut on the fill tube. See Figure 100. Make sure to not loosen the check valve during this process.

Figure 101. Hydrogen fill port switch connector Figure 100. Hydrogen fill tube 1.

H2 FILL TUBE

2.

1.

FILL PORT SWITCH CONNECTOR

5.

Use the 4 mm hex key/bit to remove the two screws attaching the fill port bracket to the lifting bracket. See Figure 102.

6.

Use the 5 mm hex key/bit to remove the four screws attaching the lifting bracket to the casting. See Figure 102.

7.

Cut the two cable ties securing the fill line in place. See Figure 102.

CHECK VALVE

3.

Disconnect the fill tube from the check valve but leave the tube hanging. See Figure 100.

4.

Remove the electrical connector. See Figure 101.

98

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Nuvera® Fuel Cell System N1800V36/N1821V36/ N1800V48/N1824V48 Service Manual

Service procedures

Figure 102. Fill line remove 1.

M6 CREW

2.

CABLE TIES

8.

Remove the fill line from the FCS and place on a work bench. See Figure 103.

9.

3.

Figure 103. Swaged nuts

M8 SCREW

1.

FILL TUBE

2.

SWAGED NUT

Install

Remove the swaged nut holding the fill tube to the back of the fill port. See Figure 103 and refer to Swagelok® procedures.

99

1.

Locate the new fill line. Attach and tighten the swage nuts. See Swagelok® procedures.

2.

Install the the new fill line into the FCS and connect to the back of the fuel port. See Figure 103.

3.

Secure to the bracket with cable ties. See Figure 102.

4.

Use the 5 mm hex key/bit to remove the four screws attaching the lifting bracket to the casting. See Figure 102.

5.

Torque to 25 N•m (18.4 lbf ft.).

6.

Use the 4 mm hex key/bit to remove the two screws attaching the fill port bracket to the lifting bracket. See Figure 102.

7.

Torque to 10 N•m (7.4 lbf ft.).

8.

Connect the electrical connector. See Figure 101.

www.nuvera.com

Service procedures 9.

Nuvera® Fuel Cell System N1800V36/N1821V36/ N1800V48/N1824V48 Service Manual

Connect the fill tube to the check valve. See Figure 100.

10. Install the main battery. See Replacing the main battery.

11. Install the left hand upper side panel and top panel. See Removing and installing the cover panels.

12. Use the combustible gas detector or Snoop™ to perform a leak check to determine if any leaks are present.

100

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Nuvera® Fuel Cell System N1800V36/N1821V36/ N1800V48/N1824V48 Service Manual

Service procedures Replacing the hydrogen fill port

Scope To remove the hydrogen fill port from the Fuel Cell System and replace with new.

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 your service provider.

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 tools required Nuvera part number

Description

71001056

Hydrogen fill port

1

N/A

Torque wrench

1

Qty.

Nuvera part number

Description

Qty.

N/A

Phillips head screwdriver

1

N/A

Hex key/bit set and driver

1

N/A

Electronic combustible gas detector or

1

N/A

or liquid leak detector (Snoop™)

1

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

Prepare 1.

Remove the FCS from the lift truck. Confirm the FCS is powered off.

2.

Remove the front panel and top panel. See Removing and installing the cover panels.

3.

Remove the pressure from the system. See H2 pressure relief.

4.

Remove the hydrogen fill line. See Replacing the hydrogen fill line.

NOTE: The following procedure describes the process for replacing the hydrogen fill port. To replace attaching parts see the Parts Manual for more information.

Remove 1.

Locate the fill port harness connector. See Figure 104.

2.

Remove the cable ties holding the harness connector to the bracket. See Figure 104.

101

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Nuvera® Fuel Cell System N1800V36/N1821V36/ N1800V48/N1824V48 Service Manual

Service procedures

Figure 105. Hydrogen fill port remove

Figure 104. Fill port harness connector 3.

1.

1.

SCREWS

CONNECTOR

2.

HARNESS

3.

Remove the two screws retaining the harness connector to the bracket. See Figure 104.

4.

Remove the four screws and slide the back off the fill port.

5.

Remove the fill port from the FCS. See Figure 105.

BACK OF THE FILL PORT

2.

SCREWS

Install 1.

Locate the fill port and align the port with the bracket.

2.

Insert the four screws to attach the fill port to the bracket and tighten until hand tight. See Figure 105.

3.

Insert the two screws to attach the harness connector to the bracket. See Figure 104.

4.

Tighten the screws. Torque to 3 N•m (2.2 lbf ft.).

5.

Use new the cable ties to retain the harness connector to the bracket. See Figure 104.

6.

Install the hydrogen fill line. See Replacing the hydrogen fill port.

7.

Install the left hand upper side panel and top panel. See Removing and installing the cover panels.

8.

Use the combustible gas detector or Snoop™ to perform a leak check to determine if any leaks are present.

102

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Nuvera® Fuel Cell System N1800V36/N1821V36/ N1800V48/N1824V48 Service Manual

Service procedures Replacing the hydrogen regulator

Nuvera part number

Description

Qty.

To remove the hydrogen regulator from the Fuel Cell System and replace with new.

N/A

9/16", 11/16”, 13/16" Open end wrench

1

Safety and warnings

N/A

Bit driver

1

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

N/A

5 mm hex bit/key

1

1.

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

N/A

5 mm hex bit/key extension

1

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 your service provider.

N/A

5.5 mm, 7 mm socket

1 ea.

N/A

Ratcheting wrench (1/4" or 3/8" drive)

1

N/A

Molykote™ 55 lubricant

1

N/A

Loctite™ 242

1

N/A

Electronic combustible gas detector

1

N/A

or liquid leak detector (Snoop™)

1

Scope

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.

Parts and tools required

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

Prepare

Nuvera part number

Description

Qty.

1.

31009311

Hydrogen regulator

Remove the FCS from the lift truck. Confirm the FCS is powered off.

1

2.

N/A

Torque wrench

1

Remove the front panel and top panel. See Removing and installing the cover panels.

3.

Remove the pressure from the system. See H2 pressure relief.

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Service procedures 4.

Nuvera® Fuel Cell System N1800V36/N1821V36/ N1800V48/N1824V48 Service Manual

Remove the hydrogen fill line. See Replacing the hydrogen fill line.

NOTE: The following procedure describes the process for replacing the hydrogen regulator. To replace attaching parts see the Parts Manual for more information.

Remove 1.

Close the manual tank valve. See Open and close the tank valve.

2.

Refer to Figure 106 and perform the following procedures to remove or disconnect components: • Remove the sensor port plug (item 1).

• Remove the hose clamp and hydrogen supply hose (item 2) from the fitting.

Leave the hose hanging.

• Remove the hydrogen supply fitting (item 3).

• Disconnect the low pressure supply valve electrical connector (item 4).

• Remove the hose clamp and bias hose from the fitting (item 5). Leave the hose hanging.

• Remove the pressure relief valves (item 7).

• Remove the bracket retaining (item 6) the pressure relief valves.

Figure 106. Regulator connections 1.

SENSOR PORT PLUG

5.

BIAS HOSE

2.

HYDROGEN SUPPLY HOSE

6.

BRACKET

3.

HYDROGEN SUPPLY FITTING

7.

PRESSURE RELIEF VALVES

4.

LOW PRESSURE SUPPLY VALVE ELECTRICAL CONNECTOR

3.

Remove the four fasteners that attach the hydrogen regulator to the tank valve. An extension may be necessary to access the fasteners. See Figure 107.

Figure 107. Regulator remove 1.

FASTENERS

4.

Remove the regulator from the tank valve.

104

2.

REGULATOR

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Nuvera® Fuel Cell System N1800V36/N1821V36/ N1800V48/N1824V48 Service Manual

Service procedures

Install 1.

Ensure the o-ring and back-up ring are clean and free of debris.

2.

Locate the new regulator and prepare it by coating the inlet fitting o-rings and back-up ring with Molykote 55.

3.

Slide the new regulator into place, aligned with the tank valve, using the dowel pins for alignment. There will be some resistance as the o-ring slides into place.

• Install the bracket retaining (item 6) the pressure relief valves.

• Install the pressure relief valves (item 7).

Torque to 13 N•m (9.6 lbf ft.).

7.

Open the manual valve and tank valve. Use the combustible gas detector or Snoop™ to perform a leak check along the perimeter of the joint to determine if any leaks are present.

8.

Install the left hand upper side panel and top panel. See Removing and installing the cover panels.

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• There is a potential for the inlet fitting oring and back-up ring to be cut or shaved –do not apply excessive force to join the tank valve and regulator together or hammer them together.

• Check for gaps between the tank valve and the regulator. No light or air gap is acceptable.

4.

Apply Loctite 242 to the fasteners and insert the fasteners to attach the regulator to the tank valve, threading by hand at first.

5.

Torque the fasteners to 5.5 to 6.5 N•m (4.1 to 5.5 lbf ft.). Apply torque marks to fastener heads.

6.

Refer to Figure 106 and perform the following procedures to install or connect components. Make sure are o-rings are regreased with Molykote 55 before installing.

• Install the sensor port plug (item 1).

• Install the hose clamp and hydrogen supply hose (item 2) to the fitting. Tighten the hose clamp. Torque to 3 N•m (2.2 lbf ft.).

• Install the hydrogen supply fitting (item 3). Torque to 13 N•m (9.6 lbf ft.).

• Connect the low pressure supply valve electrical connector (item 4).

• Install the hose clamp and bias hose to the fitting (item 5). Tighten the hose clamp. Torque to 3 N•m (2.2 lbf ft.).

Nuvera® Fuel Cell System N1800V36/N1821V36/ N1800V48/N1824V48 Service Manual

Service procedures Replacing the hydrogen recirculation pump

Nuvera part number

Description

Qty.

N/A

1

To remove the hydrogen recirculation pump from the Fuel Cell System and replace with new.

Flat head screwdriver

N/A

Bit driver

1

Safety and warnings

N/A

3 mm hex bit/key

1

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

N/A

Swivel 10 mm socket

1

N/A

Ratcheting wrench (1/4" or 3/8" drive)

1

Scope

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 your service provider.

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

1.

Remove the FCS from the lift truck. Confirm the FCS is powered off.

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

2.

Remove the top panel. See Removing and installing the cover panels.

3.

Relieve the pressure from the hydrogen line.

See H2 pressure relief.

4.

Disconnect the main battery. See Disconnecting the batteries.

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.

Parts and tools required

Prepare

NOTE: The following procedure describes the process for replacing the hydrogen recirculation pump. To replace attaching parts see the Parts Manual for more information.

Remove

Nuvera part number

Description

Qty.

N/A

31009850

1

N/A

T25 torx bit

1

N/A

Torque wrench

1

1.

Close the manual tank valve. See .

2.

Refer to Figure 108 and perform the following procedures to remove or disconnect components: • Remove the J3 harness connector from the back of the electrical box (item 4).

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Nuvera® Fuel Cell System N1800V36/N1821V36/ N1800V48/N1824V48 Service Manual

Service procedures • Remove the connector from the sensor (item 2).

• Disconnect the two harness connectors from the wire harness to the connectors (item 3) on the sensor bracket.

• Remove the two cable ties (item 5) retaining the harness to the top of the bracket.

• Slide the J3 harness out of the way to provide top access to the recirculation pump.

• Remove the two harness connectors (item 3) on the sensor bracket.

• Remove the three screws (item 1) retaining the bracket. Remove the bracket.

Figure 109. Recirculation pump hoses 1.

HOSES

2.

PUMP MOUNTING NUTS

4.

Use the 10mm swivel socket and extension to remove the four pump mounting nuts and lock washers from the isolators.

5.

Lift the pump out from the FCS from the top.

Install

Figure 108. Recirculation pump connections 1.

SCREWS

4.

J3 CONNECTOR

2.

SENSOR CONNECTOR

5.

CABLE TIES

3.

HARNESS CONNECTORS

3.

Remove the hose clamps and hoses. See Figure 109.

1.

Locate the new hydrogen recirculation pump.

2.

Install the inlet and outlet fittings and sealing washers into correct ports. See Figure 110.

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Nuvera® Fuel Cell System N1800V36/N1821V36/ N1800V48/N1824V48 Service Manual

Service procedures

• Connect the J3 harness connector to the back of the electrical box (item 4).

• Attach new two cable ties (item 5) to retain the harness to the top of the bracket.

8.

Install the top panel. See Removing and installing the cover panels.

Figure 110. Hydrogen recirculation pump fittings 1.

INLET FITTING

4.

OUTLET FITTING

2.

INLET SEALING WASHER

5.

RECIRCULATION PUMP

3.

OUTLET SEALING WASHER

3.

Torque the fasteners to 30 N•m (22.1 lbf ft.).

Apply torque marks to fastener heads.

4.

Install the hose clamps and hoses onto the new inlet and outlet fittings. See Figure 109.

Tighten the hose clamps. Torque to 3 N•m (2.2 lbf ft.).

5.

Insert the four pump mounting nuts and lock washers into the isolators.

6.

Torque to 3 N•m (2.2 lbf ft.).

7.

Refer to Figure 108 and perform the following procedures to install or connect components.

• Install the bracket and insert the three screws (item 1) to retain the bracket.

Torque to 3 N•m (2.2 lbf ft.).

• Install the two harness connectors (item 3) on the sensor bracket.

• Connect the two harness connectors from the wire harness to the connectors (item 3) on the sensor bracket.

• Connect the connector to the sensor (item 2).

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Nuvera® Fuel Cell System N1800V36/N1821V36/ N1800V48/N1824V48 Service Manual

Service procedures Replacing the hydrogen fuel tank

Scope To remove the fuel tank from the Fuel Cell System (FCS) and replace with new.

Nuvera part number

Description

Qty.

N/A

11/16" open end wrench

1

N/A

Socket set

1

N/A

Ratcheting Wrench (1/4” or 3/8” Drive)

1

N/A

Torque wrench

1

N/A

Overhead Lifting Device Capable of 2000 lbs

1

N/A

Battery Lifting Bar

1

N/A

Magnetic Lifting Device Capable of 500 lbs and Attaching to Round Objects

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 your service provider.

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 tools required Nuvera part number

Description

Qty.

31009311

Tank assembly

1

N/A

Torx bit set

1

N/A

Hex key/bit set

1

N/A

Bit driver

1

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

Prepare 1.

Remove the FCS from the lift truck. Confirm the FCS is powered off.

2.

Remove the front panel and back panel. See Removing and installing the cover panels.

3.

Remove the left hand lower side panel and right hand lower side panel. See Removing and installing the cover panels.

NOTE: The following procedure details steps for replacing the fuel tank. If any attached component must be replaced, please refer to the Parts Manual.

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Nuvera® Fuel Cell System N1800V36/N1821V36/ N1800V48/N1824V48 Service Manual

Service procedures

Remove 1.

• Disconnect the swage nut and remove the fill line (item 1) from the check valve.

Leave the hose hanging. See Swagelok® procedures.

• Disconnect the sensor electrical connector (item 2).

• Remove the hose clamp and hydrogen supply hose (item 3) from the fitting.

Leave the hose hanging.

• Disconnect the low pressure supply valve electrical connector (item 5).

• Remove the hose clamp and bilas hose (item 6) from the fitting. Leave the hose hanging.

• Disconnect the swage nuts and remove the PRD vent line (item 7). See Swagelok® procedures.

• Disconnect the tank valve electrical connectors.

With the lower side panels removed, locate the upper and lower castings and the brackets. See Figure 111.

Figure 111. Upper and lower casting 1.

SCREWS

3.

UPPER CASTING

2.

BRACKET

4.

LOWER CASTING

2.

Loosen all the screws holding the upper and lower castings together and remove the top screws completely. Leave the screws in the lower part of the brackets to keep the brackets attached to the lower casting. See Figure 111.

Figure 112. Regulator connections 1.

FILL LINE

2.

SENSOR CONNECTOR

Disconnect the main battery and low voltage battery. See Disconnecting the batteries.

3.

HYDROGEN SUPPLY HOSE

Refer to Figure 112 and perform the following procedures to remove or disconnect components.

4.

HOSE CLAMP

3.

Relieve the system of all hydrogen. See H2 pressure relief.

4.

5.

110

5.

LOW PRESSURE SUPPLY VALVE CONNECTOR

6.

BIAS HOSE

7.

PRD VENT LINE

8.

TANK VALVE ELECTRICAL CONNECTOR

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Nuvera® Fuel Cell System N1800V36/N1821V36/ N1800V48/N1824V48 Service Manual

Service procedures 6.

Once all the connections are removed, slowly lift the upper casting assembly up and out of the way using the lift points provided. Make sure to lift vertically to avoid damage to the lifting brackets. Have another technician monitor the regulator to make sure the regulator is not damaged while removing the upper casting. Set the upper casting off to the side. See Figure 113.

3.

Slowly lower the tank into the lower casting, with another technician monitoring the regulator and brackets to make sure there is no damage during tank installation.

4.

Slowly lift the upper casting assembly and lower it onto the lower casting assembly.

Make sure to lower vertically to avoid damage to the lifting brackets. Have another technician monitor the regulator to make sure the regulator is not damaged while installing the upper casting.

5.

Refer to Figure 112 and perform the following procedures to install or connect components.

• Install the fill line (item 1) to the check valve. Connect the swage nut. See Swagelok® procedures.

• Connect the sensor electrical connector (item 2).

• Install the hose clamp and hydrogen supply hose (item 3) to the fitting.

• Connect the low pressure supply valve electrical connector (item 5).

• Install the hose clamp and bilas hose (item 6) to the fitting.

• Install the PRD vent line (item 7). Connect the swage nuts. See Swagelok® procedures.

• Connect the tank valve electrical connectors.

Figure 113. Upper casting removed 7.

Attach a magnetic lifting device capable of safely lifting over 500 lbs and attaching to round objects, to the center of the hydrogen tank, making sure it is level on the top surface.

8.

Slowly lift the tank out of the lower casting, while again monitoring the regulator.

9.

Lower the tank on to a suitable transportation platform.

6.

Insert the the screws in the top part of the brackets holding the upper and lower castings together. See Figure 111.

7.

Tighten the upper and lower screws in the bracket to secure the upper and lower castings. See Figure 111. Torque to 25 N•m (18.4 lbf ft.).

8.

Install the left hand lower side panel and right hand lower side panel. See Removing and installing the cover panels.

9.

Install the front panel and back panel. See Removing and installing the cover panels.

10. Block the sides of the tank to ensure it will not roll off the transportation platform.

Install 1.

Locate the new hydrogen fuel tank.

2.

Attach a magnetic lifting device capable of safely lifting over 500 lbs and attaching to round objects, to the center of the new hydrogen tank, making sure it is level on the top surface.

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Nuvera® Fuel Cell System N1800V36/N1821V36/ N1800V48/N1824V48 Service Manual

Service procedures Replacing the hydrogen purge valve

Nuvera part number

Description

Qty.

To remove the hydrogen purge valve from the Fuel Cell System and replace with new.

N/A

1/4" Ratcheting wrench

1

Safety and warnings

N/A

Socket set

1

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

N/A

½” Wide PTFE (Teflon) Sealing Tap

1

1.

N/A

Hex key/bit set

1

31004846

Liquid leak detector (Snoop™)

1

Scope

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 your service provider.

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

Parts and tools required

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.

Nuvera part number

Description

Qty.

N/A

Hydrogen purge valve

1

N/A

Small torque wrench

1

N/A

1/4" Ratcheting wrench

1

N/A

Socket set

1

N/A

½” Wide PTFE (Teflon) Sealing Tap

1

N/A

Hex key/bit set

1

31004846

Liquid leak detector (Snoop™)

1

Parts and tools required Nuvera part number

Description

Qty.

31009847

Hydrogen purge valve

1

N/A

Small torque wrench

1

112

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Nuvera® Fuel Cell System N1800V36/N1821V36/ N1800V48/N1824V48 Service Manual

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

Prepare 1.

Remove the FCS from the lift truck. Confirm the FCS is powered off.

2.

Remove the left hand upper side panel and top panel. See Removing and installing the cover panels.

3.

Remove the pressure from the system. See H2 pressure relief.

4.

Remove the humidifier. See Replacing the humidifier.

NOTE: The following procedure describes the process for replacing the hydrogen purge valve.

To replace attaching parts see the Parts Manual for more information.

Remove 1.

Disconnect the purge valve electrical connector and remove the connector from the attachment base. See Figure 114.

Figure 115. Purge valve fittings 1.

FITTINGS

3.

HOSES

2.

SCREWS

4.

PURGE VALVE

3.

Remove the two screws (item 2, Figure 115) retaining the purge valve to the shelf.

4.

Remove the purge valve from the FCS.

5.

Remove the fittings from each end of the purge valve and set aside for installation onto new purge valve.

Install 1.

Figure 114. Purge valve connector 2.

Remove the hoses and hose clamps from the fittings at each end of the purge valve. Make sure to not damage the the valve or fittings.

See Figure 115.

Locate the fittings that were removed from the previous purge valve.

• Remove the old sealing tape from the fitting threads.

• Wrap new PTFE tape on each fitting 1-1/2 turns in a clockwise direction, viewed form the pipe end, leaving the first two threads uncovered.

NOTE: The purge valve is directional and the fittings must be installed with the ½” fitting on the inlet side of the valve and the ¼” fitting on the outlet side. The valve has markers on the bottom of the valve “P” for inlet side and “A” for outlet side.

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Nuvera® Fuel Cell System N1800V36/N1821V36/ N1800V48/N1824V48 Service Manual

Service procedures 2.

Locate the new purge valve and install the fittings on the new purge valve. Tighten 1.5 to 2 turns past finger tight.

3.

Install the new purge valve in the FCS aligned with the two holes in the shelf.

4.

Insert the two screws to retain the purge valve. Torque to 0.7 N•m (0.5 lbf ft.).

5.

Install the hoses and hose clamps to the fittings at each end of the purge valve. See Figure 115.

6.

Torque to 3 N•m (2.2 lbf ft.).

7.

Attach the connector to the attachment base.

See Figure 114.

8.

Connect the purge valve electrical connector.

See Figure 114.

9.

Connect the fill tube to the check valve. See Figure 114.

10. Install the humidifier. See Replacing the humidifier.

11. Install the left hand upper side panel and top panel. See Removing and installing the cover panels.

12. Use the combustible gas detector or Snoop™ to perform a leak check to determine if any leaks are present.

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Nuvera® Fuel Cell System N1800V36/N1821V36/ N1800V48/N1824V48 Service Manual

Service procedures Replacing the hydrogen pressure sensors

Scope To remove the high and low pressure sensors 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 your service provider.

3.

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

Nuvera part number

Description

Qty.

71000995

Low pressure sensor

2

N/A

7/8" open end wrench

1

N/A

Molykote™ 55 lubricant

1

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

Prepare 1.

Remove the FCS from the lift truck. Confirm the FCS is powered off.

2.

Remove the top panel, left hand upper side panel and right hand upper side panel. See Removing and installing the cover panels.

3.

Relieve all hydrogen pressure from the system. See H2 pressure relief.

Remove High pressure sensor

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.

Locate the high pressure sensor. See Figure 116.

2.

Disconnect the harness connector from the back of the sensor. See Figure 116.

3.

Remove the sensor from the tank valve.

Parts and tools required Nuvera part number

Description

Qty.

71001011

High pressure sensor

1

115

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Nuvera® Fuel Cell System N1800V36/N1821V36/ N1800V48/N1824V48 Service Manual

Service procedures

4.

Connect the harness connector to the back of the sensor. See Figure 116.

5.

Install all removed panels. See Removing and installing the cover panels.

6.

Use the combustible gas detector or Snoop™ to perform a leak check to determine if any leaks are present.

Low pressure sensor

Figure 116. High pressure sensor

1.

Locate the new low pressure sensors.

2.

Apply Molykote 55 lubricant to the o-ring of the sensors.

3.

Install the sensors into the fuel cell stack and torque to 13 N•m (9.7 lbf ft.). See Figure 117.

4.

Connect the harness connector to the back of each sensor. See Figure 117.

Low pressure sensor 1.

Locate the low pressure sensors. See Figure 117.

5.

Install all removed panels. See Removing and installing the cover panels.

2.

Connect the harness connector to the back of each sensor. See Figure 117.

6.

3.

Remove the sensors from the fuel cell stack.

Use the combustible gas detector or Snoop™ to perform a leak check to determine if any leaks are present.

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Figure 117. Low pressure sensors

Install High pressure sensor 1.

Locate the new high pressure sensor.

2.

Apply Molykote 55 lubricant to the o-ring of the sensor.

3.

Install the sensor into the tank valve and torque to 13 N•m (9.7 lbf ft.). See Figure 116.

Nuvera® Fuel Cell System N1800V36/N1821V36/ N1800V48/N1824V48 Service Manual

Service procedures Replacing the coolant temperature and pressure sensors

Scope To remove the coolant temperature and pressure sensors and replace with new.

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

Nuvera part number

Description

Qty.

31009820

Coolant pressure sensor

3

N/A

7/8" open end wrench

1

N/A

Molykote™ 55 lubricant

1

1.

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

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

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 your service provider.

Prepare

3.

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

DANGER

1.

Remove the FCS from the lift truck. Confirm the FCS is powered off.

2.

Remove the top panel, left hand upper side panel and right hand upper side panel. See Removing and installing the cover panels.

3.

Relieve all hydrogen pressure from the system. See H2 pressure relief.

4.

Drain coolant from the system. See Drain and fill coolant.

Remove

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 tools required Nuvera part number

Description

Qty.

31009819

Coolant temperature sensor

2

Coolant temperature sensor 1.

Locate the coolant temperature sensor connected to the pump outlet. See Figure 118.

2.

Disconnect the harness connector from the back of the sensor. See Figure 118.

3.

Use the 7/8" open end wrench to remove the sensor from the pump outlet.

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Service procedures

Nuvera® Fuel Cell System N1800V36/N1821V36/ N1800V48/N1824V48 Service Manual 2.

Disconnect the harness connector from the back of the sensor. See Figure 120.

3.

Remove the sensor from the pump outlet.

Figure 118. Coolant temperature sensor at pump outlet 4.

Locate the coolant temperature sensor connected to the fuel cell outlet. See Figure 119.

5.

Disconnect the harness connector from the back of the sensor. See Figure 119.

6.

Remove the sensor from the fuel cell outlet.

Figure 120. Coolant pressure sensor at pump outlet 4.

Locate the coolant pressure sensor connected to the fuel cell stack outlet. See Figure 121.

5.

Locate the coolant pressure sensor connected to the fuel cell stack inlet. See Figure 122.

6.

Disconnect the harness connector from the back of each sensor.

7.

Remove the sensors from the fuel cell stack.

Figure 119. Coolant temperature sensor at fuel cell outlet Coolant pressure sensor 1.

Locate the coolant pressure sensor connected to the pump outlet. See Figure 120.

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Nuvera® Fuel Cell System N1800V36/N1821V36/ N1800V48/N1824V48 Service Manual

Service procedures

4.

Connect the harness connector to the back of the sensor. See Figure 118.

5.

Install the sensor into the fuel cell outlet and torque to 13 N•m (9.7 lbf ft.). See Figure 119.

6.

Connect the harness connector to the back of the sensor. See Figure 119.

7.

Install all removed panels. See Removing and installing the cover panels.

8.

Refill the system with coolant. See Drain and fill coolant.

Coolant pressure sensor 1.

Locate the coolant pressure sensors. Wrap five layers of PTFE sealing tape around the threads.

2.

Apply Molykote 55 lubricant to the o-ring of each sensor.

3.

Install the sensor into the pump outlet and torque to 13 N•m (9.7 lbf ft.). See Figure 120.

4.

Connect the harness connector to the back of the sensor. See Figure 120.

5.

Install the sensors into the fuel cell outlet and torque to 13 N•m (9.7 lbf ft.). See Figure 121.

6.

Connect the harness connector to the back of the sensor. See Figure 121.

7.

Install the sensors into the fuel cell inlet and torque to 13 N•m (9.7 lbf ft.). See Figure 122.

8.

Connect the harness connector to the back of the sensor. See Figure 122.

9.

Install all removed panels. See Removing and installing the cover panels.

Figure 121. Coolant pressure sensor outlet

Figure 122. Coolant pressure sensor inlet

Install Coolant temperature sensor

10. Refill the system with coolant. See Drain and fill coolant.

1.

Locate the coolant temperature sensors.

Wrap five layers of PTFE sealing tape around the threads.

2.

Apply Molykote 55 lubricant to the o-ring of the sensor.

3.

Install the sensor into the pump outlet and torque to 13 N•m (9.7 lbf ft.). See Figure 118.

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Nuvera® Fuel Cell System N1800V36/N1821V36/ N1800V48/N1824V48 Service Manual

Service procedures Replacing the cathode Mass Air Flow (MAF) sensor

Nuvera part number

Description

Qty.

N/A

1

To remove the Mass Air Flow sensor and replace with new.

3 mm hex key/bit

N/A

Torque wrench

1

Safety and warnings

N/A

Molykote™ 55 lubricant

1

Scope

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.

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

Prepare

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 your service provider.

1.

Remove the FCS from the lift truck. Confirm the FCS is powered off.

2.

Remove the top panel, left hand upper side panel and right hand upper side panel. See Removing and installing the cover panels.

3.

Relieve all hydrogen pressure from the system. See H2 pressure relief.

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

4.

Drain coolant from the system. See Drain and fill coolant.

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 tools required Nuvera part number

Description

Qty.

31009854

MAF sensor

1

N/A

Bit driver

1

Remove 1.

Locate the MAF sensor attached to the backside of the air inlet manifold. See Figure 123.

2.

Disconnect the harness connector from the back of the sensor. See Figure 123.

3.

Remove the two screws that attach the MAF to the manifold. See Figure 123.

4.

Remove the sensor from the port.

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Nuvera® Fuel Cell System N1800V36/N1821V36/ N1800V48/N1824V48 Service Manual

Service procedures

Figure 123. MAF sensor

Install 1.

Locate the new MAF sensor. Wrap five layers of PTFE sealing tape around the threads.

2.

Apply Molykote 55 lubricant to the o-ring of the sensor.

3.

Install the sensor onto the manifold. Torque 3 N•m (2.2 lbf ft.). See Figure 123.

4.

Connect the harness connector to the sensor.

See Figure 123.

5.

Install all removed panels. See Removing and installing the cover panels.

121

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Nuvera® Fuel Cell System N1800V36/N1821V36/ N1800V48/N1824V48 Service Manual

Service procedures Replacing the cathode temperature and pressure (TMAP) sensors

Scope To remove the TMAP sensors 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 your service provider.

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.

Parts and tools required Nuvera part number

Description

Qty.

71001040

TMAP sensor

5

N/A

T30 Torx bit/ screwdriver

1

Nuvera part number

Description

Qty.

N/A

Ratcheting wrench (1/4" or 3/8" drive)

1

N/A

Torque wrench

1

N/A

Molykote™ 55 lubricant

1

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

Prepare 1.

Remove the FCS from the lift truck. Confirm the FCS is powered off.

2.

Remove the top panel, left hand upper side panel and right hand upper side panel. See Removing and installing the cover panels.

3.

Relieve all hydrogen pressure from the system. See H2 pressure relief.

Remove 1.

Locate the TMAP sensor attached to the backside of the air inlet manifold. See Figure 124.

2.

Disconnect the harness connector from the back of the sensor. See Figure 124.

3.

Remove the two screws that attach the TMAP to the manifold. See Figure 124.

4.

Remove the sensor from the port.

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Nuvera® Fuel Cell System N1800V36/N1821V36/ N1800V48/N1824V48 Service Manual

Service procedures

Figure 124. TMAP sensor 5.

Locate the two TMAP sensors attached to the backside of the radiator. See Figure 125.

6.

Disconnect the harness connector from each sensor. See Figure 125.

7.

Remove the screws that attach the sensors.

See Figure 125.

8.

Remove the sensors from the radiator.

Figure 125. TMAP sensors at radiator 1.

TMAP (HEAT EXCHANGER INLET/AIR COMPRESSOR OUTLET)

2.

TMAP (HEAT EXCHANGER OUTLET)

9.

Locate the two TMAP sensors attached to the fuel cell stack. See Figure 126.

10. Disconnect the harness connector from the sensors. See Figure 126.

11. Remove the screws that attach the sensors to the fuel cell stack. See Figure 126.

12. Remove the sensors.

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Nuvera® Fuel Cell System N1800V36/N1821V36/ N1800V48/N1824V48 Service Manual

Service procedures

Figure 126. TMAP sensors at fuel cell stack 1.

TMAP (FUEL CELL OUTLET)

2.

TMAP (FUEL CELL INLET)

Install 1.

Locate the new TMAP sensors. Wrap five layers of PTFE sealing tape around the threads.

2.

Apply Molykote 55 lubricant to the o-ring of each sensor.

3.

Install the sensor onto the air inlet manifold.

Insert screw and tighten. Torque to 6 N•m (4.4 lbf ft.). See Figure 124.

4.

Connect the harness connector to the sensor.

See Figure 124.

5.

Install the two sensors onto the radiator.

Insert screws and tighten. Torque to 6 N•m (4.4 lbf ft.). See Figure 125.

6.

Connect the harness connectors to the sensors. See Figure 125.

7.

Install the two sensors onto the fuel cell stack. Insert screw and tighten. Torque to 6 N•m (4.4 lbf ft.). See Figure 126.

8.

Connect the harness connectors to the sensors. See Figure 126.

9.

Install all removed panels. See Removing and installing the cover panels.

124

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Nuvera® Fuel Cell System N1800V36/N1821V36/ N1800V48/N1824V48 Service Manual

Service procedures Replacing the dewatering connector

Scope To remove the dewatering quick connect fitting from the Fuel Cell System (FCS) and replace with new.

Safety and warnings

Nuvera part number

Description

Qty.

N/A

11/16” Open End Wrench

2

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

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

Prepare

1.

1.

Remove the FCS from the lift truck. Confirm the FCS is powered off.

2.

Remove the right hand upper side panel. See Removing and installing the cover panels.

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 your service provider.

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 tools required Nuvera part number

Description

Qty.

N/A

Dewatering fitting

1

NOTE: The following procedure describes the process for removing the dewatering connector. If removing any of the attaching parts, see the Parts Manual.

Remove 1.

Make sure FCS has been dewatered before proceeding. See Nuvera® Fuel Cell System Operating Manual.

2.

Remove the hose clamp attaching the fitting to the hose. See Figure 127.

3.

Use one of the 11/16" open end wrench to hold the nut on the outside of the bracket secure (item 2, Figure 127). Use the other wrench to remove the nut on the inside of the bracket (item 3, Figure 127).

4.

Slide the dewatering quick connect fitting out the front of the FCS to remove. See Figure 127.

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Nuvera® Fuel Cell System N1800V36/N1821V36/ N1800V48/N1824V48 Service Manual

Service procedures

Figure 127. Dewatering connector fitting 1.

2.

DEWATERING QUICK DISCONNECT FITTING

3.

INSIDE NUT

4.

HOSE CLAMP

OUTSIDE NUT

Install 1.

Locate the new quck disconnect fitting.

2.

Insert the new fitting into place in the FCS. See Figure 127.

3.

Use one of the 11/16" open end wrench to hold the nut on the outside of the bracket secure (item 2, Figure 127).

4.

Install the inside nut and use the other wrench to tighten the nut on the inside of the bracket (item 3, Figure 127). Tighten to hand tight.

5.

Install the hose clamp to attach the fitting to the hose. Torque to 3 N•m (2.2 lbf ft.) See Figure 127.

6.

Install the right hand upper side panel. See Removing and installing the cover panels.

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Nuvera® Fuel Cell System N1800V36/N1821V36/ N1800V48/N1824V48 Service Manual

Service procedures Replacing the antenna

Nuvera part number

Description

Qty.

To remove the antenna from the Fuel Cell System (FCS) and replace with new.

N/A

Ratcheting wrench (1/4" or 3/8" drive)

1

Safety and warnings

N/A

Torque wrench

1

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

N/A

Cable tie cutting snips

1

Scope

1.

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

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

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 your service provider.

NOTE: The following procedure describes the process for replacing the antenna. To replace attaching parts, see the Parts Manual.

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.

Remove 1.

Locate the antenna and cut the cable tie retaining the harness. See Figure 128.

2.

Use the 2.5 mm hex bit to remove 3 screws retaining the antenna bracket to the main shelf bracket. See Figure 128.

3.

Remove the connector at the top of the antenna. See Figure 128.

4.

Remove the antenna/modem assembly.

Parts and tools required Nuvera part number

Description

Qty.

71001060

Antenna

1

N/A

Hex key/bit set and driver

1

127

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Nuvera® Fuel Cell System N1800V36/N1821V36/ N1800V48/N1824V48 Service Manual

Service procedures

Figure 128. Antenna/modem 1.

CABLE TIE

3.

CONNECTOR

2.

SCREW

4.

ANTENNA/MODEM

Install 1.

Locate the new antenna/modem assembly.

2.

Connect the connector to the top of the antenna. See Figure 128.

3.

Install the antenna in place, aligning the bracket with the holes on the main shelf bracket. Figure 128.

4.

Insert the three screws to retain the antenna bracket to the main shelf bracket. See Figure 128. Torque to 3 N•m (2.2 lbf ft.).

5.

Install the cable tie to retain the harness. See Figure 128.

6.

Install the top panel. See Removing and installing the cover panels.

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Nuvera® Fuel Cell System N1800V36/N1821V36/ N1800V48/N1824V48 Service Manual

Service procedures Replacing the water reservoir

Nuvera part number

Description

Qty.

To remove the water reservoir and replace with new.

N/A

Flat head screwdriver

1

Safety and warnings

N/A

Ratcheting Wrench (1/4” or 3/8” Drive)

1

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

N/A

Torque Wrench

1

Scope

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 your service provider.

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.

Parts and materials required Nuvera part number

Description

Qty.

31009835

Reservoir

1

N/A

Hex Key/Bit set

1

N/A

Bit driver

1

NOTE: The following procedure describes the process for removing the water reservoir. If removing any of the attaching parts, see the Parts Manual.

Prepare 1.

Remove the FCS from the lift truck. Confirm the FCS is powered off.

2.

Remove the top panel and right hand upper side panel. See Removing and installing the cover panels.

Remove 1.

Remove the main battery. See Replacing the main battery.

2.

Remove the main electrical box. See Replacing the main electrical box.

3.

Remove the air filter. See Replacing the air filter.

4.

Remove the dewatering quick connect. See Replacing the dewatering connector.

5.

Disconnect the electrical connectors from the air manifold sensors. See Figure 129.

129

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Nuvera® Fuel Cell System N1800V36/N1821V36/ N1800V48/N1824V48 Service Manual

Service procedures

Figure 130. Reservoir bias hose

Figure 129. Water reservoir connections 1.

RESERVOIR INLET HOSE

2.

HOSE CLAMP

3.

PURGE HOSE

4.

HOSE CLAMP

5.

ELECTRICAL CONNECTORS

6.

Remove the hose clamp (item 2, Figure 129) and reservoir inlet hose (item, 1).

7.

Remove the hose clamp (item 4, Figure 129) and purge hose (item, 3).

8.

Cut the zip ties from the 1/4" reservoir bias hose. See Figure 130.

1.

HOSE CLAMP

4.

RESERVOIR BIAS HOSE

2.

EXHAUST OUTLET HOSE

5.

ZIP TIES

3.

HOSE CLAMP

9.

Remove the hose clamp and bias line (item 3 and 4, Figure 130) from the air compressor.

10. Remove the hose clamp and exhaust outlet hose (item 1 and 2, Figure 130) from the air compressor.

11. Remove the hose clamps and inlet hose (item 1 and 2, Figure 131) from the air manifold.

12. Remove the hose clamps and outlet hose (item 4 and 5, Figure 131) from the air manifold.

13. From the main battery side, remove the three M4 flat head screws retaining the air manifold underneath the main electrical box shelf. See Figure 131. Remove the air manifold.

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Nuvera® Fuel Cell System N1800V36/N1821V36/ N1800V48/N1824V48 Service Manual

Service procedures

Figure 131. Air manifold connections 1.

HOSE CLAMPS

4.

HOSE CLAMPS

2.

INLET HOSE

5.

OUTLET HOSE

3.

M4 FLAT HEAD SCREWS

14. Remove the three M4 screws retaining the cathode air filter port to the back of the shelf.

Remove the cathode air filter port. See Figure 132.

Figure 132. Mounting screws 1.

RESERVOIR MOUNTING SCREWS

2.

CATHODE AIR FILTER PORT MOUNTING SCREWS

15. Remove the two M4 screws retaining the reservoir. See Figure 132.

3.

CATHODE AIR FILTER PORT

16. Slide the reservoir out from the right side.

Install 1.

Install the new water reservoir in place, aligned with the two holes in the bracket. See Figure 132.

2.

Insert the two M4 screws to attach the reservoir to the bracket. See Figure 132.

Torque to 3 N•m (2.2 lbf ft.).

3.

Install the new cathode air filter port in place, aligned with the four holes in the bracket. See Figure 132.

4.

Insert the four M4 screws to attach the air filter port to the bracket. See Figure 132.

Torque to 3 N•m (2.2 lbf ft.).

5.

Install the air manifold aligned with the three holes on the bracket. See Figure 131.

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Nuvera® Fuel Cell System N1800V36/N1821V36/ N1800V48/N1824V48 Service Manual

Service procedures 6.

Insert the three M4 flat head screws from underneath the main electrical box shelf, to attach the air manifold. See Figure 131.

Torque to 3 N•m (2.2 lbf ft.).

7.

Install the outlet hose and hose clamps (item 4 and 5, Figure 131) to the air manifold.

8.

Install the inlet hose and hose clamps (item 1 and 2, Figure 131) to the air manifold.

9.

Install the exhaust outlet hose and hose clamps (item 1 and 2, Figure 130) to the air compressor.

3.

Remove the three screws holding the fill port switch electrical connector to the bracket.

See Figure 133.

10. Install the bias hose and hose clamps (item 3 and 4, Figure 130) to the air compressor.

11. Attach the bias hose with new zip ties. See Figure 130.

12. Install the purge hose and hose clamp (item 3 and 4, Figure 129).

13. Install the reservoir inlet hose and hose clamp (item 1 and 2, Figure 129).

14. Connect the electrical connectors to the sensors on the air manifold. See Figure 129.

Figure 133. Fill port harness connector 1.

SWAGE NUT

15. Install the dewatering quick connect. See Replacing the dewatering connector.

2.

SCREWS

16. Install the air filter. See Replacing the air filter.

4.

Remove the contact block from the back of the emergency stop. See Replacing the E-Stop contact block.

5.

Disconnect the AS6 connector from the bottom of the hydrogen leak sensor. See Replacing the hydrogen pressure sensors.

6.

Use a socket to loosen the hose connecting the dewatering quick connect to the water reservoir.

7.

Disconnect the start button harness connector from the back of the start button.

See Figure 134.

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17. Install the main electrical box. See Replacing the main electrical box.

18. Install the main battery. See Replacing the main battery.

19. Install the top panel and right hand upper side panel. See Removing and installing the cover panels.

Remove 1.

Disconnect the low voltage battery. See Disconnecting the batteries.

2.

Remove the fill line. See Replacing the hydrogen fill line.

3.

CONNECTOR

Nuvera® Fuel Cell System N1800V36/N1821V36/ N1800V48/N1824V48 Service Manual

Service procedures

Figure 134. Start button 1.

START BUTTON

3.

START BUTTON CONNECTOR

2.

START BUTTON NUT

8.

Disconnect the J1 harness from the data port connector. See Figure 135.

Figure 136. Operator interface 1.

FLANGE HEAD BOLTS

2.

OPERATOR INTERFACE BRACKET

10. Use a socket to remove the clamps on both hoses going into the top of the water reservoir. Once clamps are removed, slide hoses off fittings on tank.

11. Disconnect the positive bus bar on the back of the fuel cell: • Remove flat head Torx screws (item 1, Figure 137) from the positive terminal of the fuel cell.

• Disconnect the other end of the bus bar from the contactor (item 4, Figure 137).

• Remove the bus bar from unit.

Figure 135. J1, J2, J3 connectors 1.

J3

3.

J1

2.

J2

9.

Use a socket to remove the two flange head bolts from the front of the operator interface bracket. Remove the operator interface bracket. See Figure 136.

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Nuvera® Fuel Cell System N1800V36/N1821V36/ N1800V48/N1824V48 Service Manual

Service procedures

Figure 137. Positive bus bar 1.

TORX SCREW

4.

STACK CONTACTOR

2.

BUTTON HEAD SCREW

5.

POSITIVE BUS BAR

3.

FLANGE NUT

Figure 139. Water reservoir mounting (rear) A. Access for socket extension

12. The water reservoir is held in place by three screws:

1.

• Use a hex bit to remove the button head screw located on the outside of the of the fuel cell shelf. See Figure 138.

• Use a socket and extension to remove the flange head screw located on the rear of the of the fuel cell shelf. See Figure 139.

• Use a socket to remove the flange head screw located on the inside of the of the fuel cell shelf. See Figure 140.

FLANGE SCREW

Figure 140. Water reservoir mounting (center) 1.

FLANGE SCREW

13. Remove the water reservoir out the front of the system.

Install 1.

Install the new water reservoir into the FCS.

2.

Secure the water reservoir in place by inserting the three screws:

Figure 138. Water reservoir 1.

BUTTON HEAD SCREW

2.

MOUNTING

3.

• Insert the button head screw on the outside of the of the fuel cell shelf. See Figure 138. Torque to 3 N•m (2.2 lbf ft.).

WATER RESERVOIR

134

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Nuvera® Fuel Cell System N1800V36/N1821V36/ N1800V48/N1824V48 Service Manual

Service procedures • Insert the flange head screw on the rear of the of the fuel cell shelf. See Figure 139. Torque to 3 N•m (2.2 lbf ft.).

• Insert the flange head screw on the inside of the of the fuel cell shelf. See Figure 140. Torque to 3 N•m (2.2 lbf ft.).

3.

12. Install the fill line. See Replacing the hydrogen fill line.

13. Connect the low voltage battery. See Disconnecting the batteries.

14. Install the top panel and right hand side panel and front panel. See Removing and installing the cover panels.

Install the positive bus bar on the back of the fuel cell: • Align the bus bar in place.

• Insert the flat head Torx screws (item 1, Figure 137) to the positive terminal of the fuel cell.

• Connect the other end of the bus bar to the contactor (item 4, Figure 137) and install nut to secure.

4.

Attach both into the top of the water reservoir. Tighten hose clamps. Torque to 3 N•m (2.2 lbf ft.).

5.

Align the operator interface bracket in place.

See Figure 136. Insert the two flange head bolts to secure the operator interface bracket to the front of the FCS. Torque to 6 N•m (4.4 lbf ft.).

6.

Connect the J1 harness to the data port connector. See Figure 135.

7.

Connect the start button harness connector to the back of the start button. See Figure 134.

8.

Attach the hose connecting the dewatering quick connect to the water reservoir.

9.

Connect the AS6 connector to the bottom of the hydrogen leak sensor. See Replacing the hydrogen pressure sensors.

10. Install the contact block to the back of the emergency stop. See Replacing the E-Stop contact block.

11. Insert the three screws to retain the fill port switch electrical connector to the bracket.

See Figure 133.

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Nuvera® Fuel Cell System N1800V36/N1821V36/ N1800V48/N1824V48 Service Manual

Service procedures Replacing the main electrical box

Nuvera part number

Description

Qty.

To remove the main electrical box and replace with new.

N/A

Ratcheting Wrench (1/4” or 3/8” Drive)

1

Safety and warnings

N/A

Torque Wrench

1

Scope

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 your service provider.

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.

31009843

Electrical box

1

N/A

2.5mm Hex Key/Bit

1

N/A

1/2" socket

Prepare 1.

Remove the FCS from the lift truck. Confirm the FCS is powered off.

2.

Remove the top panel, front panel and right hand upper side panel. See Removing and installing the cover panels.

NOTE: The following procedure describes the process for removing the electrical box. If removing any of the attaching parts, see the Parts Manual.

Remove 1.

Remove the main battery. See Replacing the main battery.

2.

Disconnect the low voltage battery. See Disconnecting the batteries.

3.

Remove the main power cables Replacing the power cables.

4.

Disconnect the three round harness connectors from the electrical box. See Figure 141.

5.

Remove the three screws and disconnect the three main busbar connections from the back of the electrical box. See Figure 141.

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Nuvera® Fuel Cell System N1800V36/N1821V36/ N1800V48/N1824V48 Service Manual

Service procedures

Figure 141. Main electrical box connections 1.

RESERVOIR INLET HOSE

3.

SCREWS

2.

BUSBARS

6.

Remove the three M6 screws retaining the main electrical box to the shelf in the FCS. See Figure 142.

7.

Lift the main electrical box up and out of the FCS to remove. See Figure 142.

2.

Insert the three screws to attach the main electrical box. See Figure 141. Torque to 10 N•m (13.6 lbf ft.).

3.

Insert the three screws to connect the three main busbar connections to the back of the electrical box. See Figure 141.

4.

Torque to 6 N•m (4.4 lbf ft.).

5.

Connect the three round harness connectors to the electrical box. See Figure 141.

6.

Attach the main power cables Replacing the power cables.

7.

Connect the low voltage battery. See Disconnecting the batteries.

8.

Install the main battery. See Replacing the main battery.

9.

Install the top panel, front panel and right hand upper side panel. See Removing and installing the cover panels.

Figure 142. Main electrical box

Install 1.

Install the main electrical box into the FCS aligned with the three holes. See Figure 141.

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Nuvera® Fuel Cell System N1800V36/N1821V36/ N1800V48/N1824V48 Service Manual

Service procedures Replacing the 24V DCDC

Scope To remove the 24V DCDC and replace with new.

Description

Qty.

N/A

Torque Wrench

1

Prepare

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 your service provider.

3.

Nuvera part number

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 FCS from the lift truck. Confirm the FCS is powered off.

2.

Remove the top panel and right hand upper side panel. See Removing and installing the cover panels.

NOTE: The following procedure describes the process for removing the 24V DCDC. If removing any of the attaching parts, see the Parts Manual.

Remove 1.

Remove the main electrical box. See Replacing the main electrical box.

2.

Remove the main DCDC. See Replacing the DC/DC assembly.

NOTE: Take notice of the labels on each wire connections before disconnecting, to aid in reconnecting.

3.

Disconnect the wire connections from the 24V DCDC. See Figure 143.

Parts and materials required Nuvera part number

Description

Qty.

31009881

24V DCDC

1

N/A

2.5mm Hex Key/Bit

1

N/A

Phillips head screwdriver

1

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Nuvera® Fuel Cell System N1800V36/N1821V36/ N1800V48/N1824V48 Service Manual

Service procedures

Figure 144. 24V DCDC screws

Install 1.

Install the 24V DCDC to the FCS aligned with the three holes on the back of the main electrical box. See Figure 144.

2.

Insert the three screws to attach the 24V DCDC to the main electrical box. See Figure 144. Torque to 3 N•m (2.2 lbf ft.).

3.

Connect the wire connections to the correct ports on the 24V DCDC. See Figure 143.

4.

Remove the main DCDC. See Replacing the DC/DC assembly.

5.

Install the main electrical box. See Replacing the main electrical box..

6.

Install the top panel and right hand upper side panel. See Removing and installing the cover panels.

Figure 143. 24V DCDC connections 1.

ST24_DCDC_0

4.

DCDC_GND_2

2.

DCDC_GND_OUT

5.

ST24_DCDC_1

3.

DCDC_GND

4.

Remove the three screws at the back of the main electrical box, retaining the 24V DCDC to the electrical box. See Figure 144.

5.

Remove the 24V DCDC from the FCS. See Figure 144.

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Nuvera® Fuel Cell System N1800V36/N1821V36/ N1800V48/N1824V48 Service Manual

Service procedures Replacing the pre-charge resistor

Nuvera part number

Description

Qty.

To remove the pre-charge resistor from the Fuel Cell System and replace with new.

N/A

Ratcheting wrench (1/4” or 3/8” Drive)

1

Safety and warnings

N/A

Torque wrench

1

N/A

7 mm socket

1

N/A

Phillips head screw

1

N/A

3 mm hex key

1

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 your service provider.

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.

Parts and tools required Nuvera part number

Description

Qty.

71001165

Pre-charge resistor

1

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

Prepare 1.

Remove the FCS from the lift truck. Confirm the FCS is powered off.

2.

Remove the left hand upper side panel. See Removing and installing the cover panels.

NOTE: The following procedure describes the process for replacing the pre-charge resistor. To replace attaching parts see the Parts Manual for more information.

Remove 1.

Remove the positive and negative main battery bus bars. See Disconnecting the batteries.

2.

Remove the M4 locknuts retaining the two resistor wires. See Figure 145.

3.

Remove the two mounting screws securing the resistor to the bracket. See Figure 145.

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Service procedures

Install 1.

Locate the resistor and connect the wires from the old resistor.

2.

Align the resistor with the two holes on the bracket. See Figure 145.

3.

Install the two M4 screws to secure the resistor to the bracket. See Figure 145.

Torque to 3 N•m (2.2 lbf ft.).

4.

Install the M4 locknuts to secure the resistor wires to the busbar. See Figure 145. Torque to 3 N•m (2.2 lbf ft.).

5.

Connect the main battery bus bars. See Disconnecting the batteries.

6.

Install the left hand upper side panel. See Removing and installing the cover panels.

Figure 145. Pre-charge resistor 1.

M4 LOCKNUTS

4.

RESISTOR

2.

RESISTOR WIRES

5.

BRACKET

3.

MOUNTING SCREWS

4.

Remove the resistor and disconnect the wires.

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Nuvera® Fuel Cell System N1800V36/N1821V36/ N1800V48/N1824V48 Service Manual

Storage procedures Storage

5.

Place into storage.

When storing the Nuvera® Fuel Cell System for any amount of time, the storage environment must be cool, dry, and well-ventilated. The ambient temperature must not exceed 35°C (95°F) or drop below 2°C (35.6°F).

Avoid exposing the FCS to: • • • •

Direct sunlight High humidity Severe vibrations Corrosive gases

Figure 146. Water reservoir drain

Mid-term storage The following sections outline the specific requirements for FCS storage dependant on the anticipated length of storage desired.

Mid-term storage is defined as storage time that will exceed 1 month in duration, but not to exceed 3 months. To properly prepare a unit for mid-term storage the following steps must be taken:

Short-term storage Short-term storage is defined as storage time of less than 1 month in duration. To properly prepare a unit for short-term storage the following steps must be taken:

1.

Remove the FCS from the lift truck and place it on a pallet. See Removing the fuel cell system in Nuvera® Fuel Cell System-Installation manual.

1.

Remove the FCS from the lift truck and place it on pallet. See Removing the fuel cell system in Nuvera® Fuel Cell System-Installation manual.

2.

Insert a 5.5 mm hex socket in the manual tank valve. Close the manual tank valve by turning the hex socket clockwise. Tighten to 3-5N-m (2.2-3.7 ft-lbs).

2.

Insert a hex key in the manual tank valve.

Close the manual tank valve by turning the hex key clockwise. Tighten to 3-5N-m (2.2-3.7 ft-lbs).

3.

Connect the condensate water hose from the hydrogen filling station to the water reservoir drain on the FCS (see ). Drain condensate water from the reservoir.

3.

Connect the condensate water hose from the hydrogen filling station to the water reservoir drain on the FCS (see Figure 146). Drain condensate water from the reservoir.

4.

Remove the LH side panel.

5.

Disconnect the negative bus bar from the main battery (voltage dependent upon system specification). See Figure 147.

4.

Secure the FCS to the pallet.

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Storage procedures

Figure 147. Battery busbars 1.

MAIN BATTERY

2.

POSITIVE BUSBAR

3.

NEGATIVE BUSBAR

Long-term storage Long-term storage is defined as storage time that will exceed 3 months in duration. The process for long-term storage includes the procedures for mid-term storage with added details to address battery voltage. In the event that long-term storage is required, contact your HYG service representative to review a plan to ensure a charge and discharge of current into the main battery can occur to keep the SOC between 40% and 60% for the requested timeframe.

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Nuvera® Fuel Cell System N1800V36/N1821V36/ N1800V48/N1824V48 Service Manual

Storage procedures Commissioning the Nuvera® fuel cell system after storage

3.

When a FCS is pulled from storage an onsite recommissioning process must occur before it can be placed back into service. The following steps outline the process to evaluate the FCS unit prior to reinstallation into a lift truck.

• Pending duration of storage time (shortterm, mid-term, or long-term), the battery negative bus bar may need to be reinstalled along with the 5A fuse that was removed from the inline fuse holder on the low voltage (12V) battery. In this case the following must be performed: 1.

Remove the LH side panel.

2.

Install negative battery busbar. See Storage.

144

Insert the screws to retain the negative battery busbar. Tighten to standard torque.

• Inspect ventilation zones to confirm they are free of any blockage or debris.

• Remove the radiator cap and check the coolant level. If the coolant level is below the neck of the radiator, fill coolant until the level reaches the neck of the radiator cap.

Reinstall radiator cap.

• Insert a hex key through the hole in the front panel, and into the manual shut-off valve. Turn the manual shut-off valve counterclockwise until it is fully open.

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Periodic maintenance procedures

Nuvera® Fuel Cell System N1800V36/N1821V36/ N1800V48/N1824V48 Service Manual

Periodic maintenance procedure schedule Service action Check power cables*

Interval hours

Procedure

Daily

N/A

Check coolant conductivity • Replace 3 months/500 hrs DI filter as needed

Coolant conductivity check Replacing the DI filter

Check coolant level (visual inspection)

Visual coolant check

3 months/500 hrs

Change air filter 6 months/1000 hrs

Replacing the air filter

Check the hydrogen fill line

6 months/1000 hrs

Replacing the hydrogen fill line

Check/clean radiator

12 months/2000 hrs

Clean and inspect radiator

Clean particulate filter

First time: 3 months/500 hrs Additional procedures: 12 months/2000 hrs

Coolant maintenance and filtration

Check 12 months/2000 hrs emergency stop

Inspect the emergency stop button

Change main battery

10,000 hrs

Replacing the main battery

Change 12V battery

10,000 hrs

Replacing the 12V batteries

Change air compressor

10,000 hrs

Replacing the air compressor

Change coolant 10,000 hrs pump

Replacing the coolant pump

Change stack

10,000 hrs

Replacing the fuel cell stack

Change humidifier

10,000 hrs

Replacing the humidifier

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Periodic maintenance procedures

Service action

Nuvera® Fuel Cell System N1800V36/N1821V36/ N1800V48/N1824V48 Service Manual

Interval hours

Procedure

Change hydrogen recirculation pump

10,000 hrs

Replacing the hydrogen recirculation pump

Change fuel fill port

5 years

Replacing the hydrogen fill port

Change hydrogen tank assembly

10 years/2,000 fills

Replacing the hydrogen fuel tank

*Visually inspect the power cables for cuts or abrasions to the outer coverings. Replace the power cables if necessary.

Clean and inspect radiator

3.

Scope To clean or inspect the radiator based on the interval listed in the Periodic Maintenance Schedule.

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.

Safety and warnings 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 used. If you feel that you are not qualified to perform this procedure, contact your service provider.

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

Inspect and clean Over time, the radiator has the potential to lose effectiveness due to layers of dust developing on the radiator fins. This loss in effectiveness is highly dependent on the environment. The aluminum fins of the radiator should be inspected and cleaned at the following intervals: • Visually inspect (with side and rear panels removed) every 12months/2000 hours.

• Inspect for signs of heavy dust build-up as well as any damage to fins or cooling fan.

If there is a dust booth available at the customer site, using compressed air to blow out the radiator is also acceptable if contained within the dust booth.

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Periodic maintenance procedures

Nuvera® Fuel Cell System N1800V36/N1821V36/ N1800V48/N1824V48 Service Manual

• Clean radiator fins with vacuum every 12months/2000 hours. This can be done by removing the rear panel.

• If routine vacuum cleanings are no longer effective, consider a thorough cleaning of the radiator by removing it from the system and washing with soap and water.

• The FCS uses a specially designed low conductivity coolant (see Table 2) to help decrease the possibility of the coolant becoming a path for electrical conductivity.

• In addition to low conductivity coolant, a deionizing (DI) filter is also used to help keep the conductivity of the coolant within specifications.

• These filters, however, have a finite life and must be changed when they can no longer keep coolant conductivity below the maximum value provided in Table 3.

• Once coolant conductivity is found to be outside of the allowable range, the deionizing filter must be replaced. See Replacing the DI filter for procedure.

• Locate the DI filter. See Figure 148.

• A conductivity meter should be used to determine if a DI Filter needs to be replaced. See Replacing the DI filter for procedure.

Coolant maintenance and filtration

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 your service provider.

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.

Inspect and clean • Coolant maintenance in FCS is especially important for safety of the operator as well as reliable operation of the FCS.

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Periodic maintenance procedures

Nuvera® Fuel Cell System N1800V36/N1821V36/ N1800V48/N1824V48 Service Manual

• Along with checking conductivity, the coolant particulate filter should be flushed to remove any contaminates that accumulate in the filter. See Figure 148. To replace the coolant particulate filter see Replacing the coolant filter/manifold for procedure.

Figure 149. DI filter and drain 1.

HOSE CLAMP

4.

DI FILTER

2.

SCREW

5.

COOLANT HOSE

3.

DI FILTER CLAMP

6.

DRAIN HOSE

Table 2. Coolant and Deionizing filter specifications Part number

Vendor informatio n

Coolant

60 ounces 31009749

DynaleneLCEG50

DI filter

1

N/A

Coolant item Figure 148. DI filter and drain DI filterCoolant particulate filter/drain

System quantity

31009971

Table 3. Service intervals for coolant system components Item check

Interval

Coolant conductivity

Every 3 month/500 hours

Replace DI filter if conductivity is over 5μS/cm

Particulate filter flush

Check at first 3 month/500 hours Then every 12 months/2000 hours thereafter

One second opening of valve. Top heat exchanger off after flush

148

Action

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Periodic maintenance procedures

Nuvera® Fuel Cell System N1800V36/N1821V36/ N1800V48/N1824V48 Service Manual

Table 3. Service intervals for coolant system components (Continued) Item check

Interval

Visual coolant check

Every 3 month/500 hours

Action Add coolant as needed to the top of the radiator neck

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Periodic maintenance procedures Visual coolant check

Scope To visually inspect coolant level based on the interval listed in the Periodic Maintenance Schedule.

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 your service provider.

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.

Nuvera part number

Description

Qty.

N/A

Funnel with integrated mesh strainer

1

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

WARNING The coolant may be hot. Do not remove the coolant if the radiator cap is warm.

WARNING Care should be taken when handling coolant. Consult MSDS for handling instructions.

Procedure 1.

Remove the FCS from the lift truck. Confirm the FCS is powered off.

2.

Locate the radiator cap. See Figure 150.

3.

Remove the radiator cap and check the fluid level. See Figure 150.

4.

If coolant level is below the radiator neck, fill the coolant to the neck of the radiator.

5.

Reinstall the radiator cap.

Parts and tools required Nuvera part number

Description

Qty.

N/A

Plastic coolant container

1

150

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Periodic maintenance procedures

Nuvera® Fuel Cell System N1800V36/N1821V36/ N1800V48/N1824V48 Service Manual

Figure 150. Radiator cap 1.

RADIATOR CAP

Figure 151. Radiator cap

Procedure 1.

Remove the FCS from the lift truck. Confirm the FCS is powered off.

2.

Locate the radiator cap. See Figure 151.

3.

Remove the radiator cap and check the fluid level. See Figure 151.

4.

If coolant level is below the radiator neck, fill the coolant to the neck of the radiator.

5.

Reinstall the radiator cap.

1.

151

RADIATOR CAP

2.

COOLANT CAP

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Nuvera® Fuel Cell System N1800V36/N1821V36/ N1800V48/N1824V48 Service Manual

Periodic maintenance procedures

Parts and tools required

Coolant conductivity check

Scope

Table 4. Required tools

To inspect coolant conductivity based on the interval listed in the Periodic Maintenance Schedule.

Safety and warnings

Nuvera part number

Description

Qty.

N/A

Liquid conductivity meter kit (Extech EC400 or equivalent)

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.

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

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 your service provider.

Prepare

3.

1.

Remove the FCS from the lift truck. Confirm the FCS is powered off.

2.

Remove the right hand side panel. See Removing and installing the cover panels.

Procedure

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.

Confirm the heat exchanger is at room temperature.

2.

Locate the coolant parrticulate filter. See Figure 152.

3.

Slowly open the coolant particulate filter valve. See Figure 152.

• The conductivity meter kit in Table 4 table should include a cup for samples. Consult the meter user manual for proper meter operation.

WARNING The coolant may be hot. Do not remove the coolant if the radiator/heat exchanger cap is warm.

Care should be taken when handling coolant.

Consult MSDS for handling instructions.

4.

If coolant conductivity has increased above the maximum value provided in Table 5, replace the DI filters. See Replacing the DI filter.

5.

Once check is complete, return the sample fluid back to the system by removing the radiator cap and pouring the fluid back into radiator.

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Periodic maintenance procedures 6.

Nuvera® Fuel Cell System N1800V36/N1821V36/ N1800V48/N1824V48 Service Manual

Reinstall the radiator cap.

Figure 152. DI filter and coolant particulate filter 1.

DI FILTER

2.

COOLANT PARTICULATE FILTER

Table 5. Service intervals for coolant system components Item check

Interval

Action

Coolant conductivity

60 ounces

Replace DI filter if conductivity is over 40μS

Particulate filter flush

Check at first 3 month/500 hours Then every 12 months/2000 hours thereafter

One second opening of valve. Top heat exchanger off after flush

Visual coolant check

Every 3 month/500 hours

Add coolant as needed to the top of the radiator neck

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Periodic maintenance procedures

Nuvera® Fuel Cell System N1800V36/N1821V36/ N1800V48/N1824V48 Service Manual

H2 pressure relief

Prepare

Scope

1.

To remove hydrogen pressure from the Fuel Cell System prior ro service.

Move the lift truck to a well-ventilated area away from any source of igition.

2.

Remove the front panel. See Removing and installing the cover panels.

Safety and warnings

Procedure

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

1.

1.

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

Use a 5.5 mm socket to close the manual tank valve. See Figure 153.

2.

Start the FCS and allow it to proceed through the start up sequence.

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 your service provider.

3.

The system will purge itself and shutdown due to low stack pressure. This will bleed the system of any hydrogen.

4.

Shut the FCS down. Then attempt another start up sequence.

5.

After the system faults again, shut the system off.

6.

Locate the pressure relief valve (PRV). See Figure 153.

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.

CAUTION It is good practice to always assume all stainless steel tubing and regulators are pressurized. Pressure must be relieved before servicing any of these components.

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Periodic maintenance procedures

Nuvera® Fuel Cell System N1800V36/N1821V36/ N1800V48/N1824V48 Service Manual

Figure 153. Hydrogen pressure relief 1.

PRV

7.

Slowly and lightly pull up on the “mushroom cap”.

2.

MANUAL TANK VALVE

• The cap is spring loaded and will return to its resting location.

• You should feel the cap rise with some upward force.

• You may hear some gas relief from the cap.

8.

Repeat the cap “pull-up” 2-3 times or until there is no further audible gas relief.

9.

Care should still be taken when removing connections. Remove slowly.

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Periodic maintenance procedures

Nuvera® Fuel Cell System N1800V36/N1821V36/ N1800V48/N1824V48 Service Manual

Inspect the emergency stop button

Inspect

Scope

1.

Locate the E-stop button. See Figure 154.

2.

Inspect the E-stop button for any signs of damage. If damaged replace. See Replacing the emergency stop button.

To inspect the emergency stop (E-stop) button from the Fuel Cell System (FCS) and confirm it is functioning properly.

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 your service provider.

3.

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

Figure 154. E-stop button 1.

E-STOP BUTTON

2.

SECUREMENT RING

3.

With the system on, press the E-stop button and verify the system immediately shut down.

DANGER

Prepare Remove the FCS from the lift truck. Confirm the FCS is powered off.

2.

Remove the top panel. See Removing and installing the cover panels.

LATCH TO CONTACT BLOCK

• If system remains on, use the start button to shut system down.

• Inspect contact block connections. See Replacing the E-Stop contact block.

• Turn system back on and attempt to shut system down with emergency stop. If system fails the shutdwon test after the contactact block inspection, replace the contact block. See Replacing the E-Stop contact block.

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.

3.

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Special Tools Special tools Part number

Description

31009515

USB2 CAN peak systems dongle

31009516

User Interface Harness (Infintium USER CAN interface)

31009517

(SW) Winflash

31009518

(SW) OpenBLT Bootloader

31009519

(SW) PCAN explorer

31004846

Combustible gas detector

Part number

Description

31009521

Optional 8" suction cup-battery removal

31004779

Liquid leak detector

31009749

Dynalene LC-EG 50 Conductivity meter Female quick-connect (Coolant drain) Pressure test kit w/ Radiator cap adapter

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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