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

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

FILE DETAILS:

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

Language : English
Pages : 196
Downloadable : Yes
File Type : PDF

IMAGES PREVIEW OF THE MANUAL:

TABLE OF CONTENTS:

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

List of Figures 14
General Information 21
Safety information 21
Personal Protective Equipment (PPE) 21
General hazards, warnings, and cautionary statements 22
Hydrogen-specific concerns 23
Swagelok® fitting procedures 24
Swagelok® procedures 24
Scope 24
Safety and warnings 24
Tools required 24
Initial seating 24
Disassembly and reseating 26
Preparing for service and maintenance 27
Components of the Nuvera® fuel cell system 27
Warning labels 28
Required procedures prior to service 29
Scope 29
Preparing the truck and removing the fuel cell 30
Scope 30
Safety and warnings 30
Tools required 30
Secure the truck 30
Prepare the truck 30
Remove the Fuel Cell System 30
Preparing the Nuvera fuel cell system for service 31
Scope 31
Safety and warnings 31
Tools required 31
Remove the air filter access panel 31
Install the air filter access panel 32
Discharging and recharging the ultracapacitors 33
Scope 33
Safety and warnings 33
Tools required 33
Discharge the ultracapacitors 33
Recharge the ultracapacitors 34
Removing and installing the main cover 36
Scope 36
Safety and warnings 36
Tools required 36
Discharge ultracapacitors 36
Remove main cover 36
Install main cover 38
Remove and replace lifting eye plate 38
Working with charged ultracapacitors with cover removed 39
Scope 39
Safety and warnings 39
Tools required 39
Procedure 40
Personal Protective Equipment (PPE) 40
Remove main cover 40
Working with charged ultracapacitors 40
Start into off mode 42
Safety and warnings 42
Tools required 42
Start into off mode 42
Leak check coolant loop 44
Safety and warnings 44
Tools required 44
Leak check coolant loop 44
Leak check anode loop 46
Safety and warnings 46
Tools required 46
Leak check anode loop 46
Leak check H2 plumbing 48
Safety and warnings 48
Tools required 48
Pressurize H2 Plumbing via Nuvera® Fuel Cell System Service Tool 48
Vent hydrogen from engine plumbing lines 50
Safety and warnings 50
Tools required 50
Set up for external supply of nominal bus voltage 52
Safety and warnings 52
Tools required 52
Revert to normal ultracaps connection 54
Safety and warnings 54
Installing Vector VN1610 drivers 55
Safety and warnings 55
Parts and materials required 55
Install 55
Retrieving data from vector data-logger 57
Safety and warnings 57
Parts and materials required 57
Load the software 57
Procedure 58
Descriptions of adopted conversion profiles 60
General Settings 60
Advanced Settings 60
Splitting Options 61
Programming the VSM (Vehicle System Manager) 62
Safety and warnings 62
Parts and materials required 62
Setup 62
Install 62
Program 63
Set up flags for VSM software 3 0 0 66
Safety and warnings 66
Tools required 66
Procedure 66
Removing and installing the engine sled 69
Scope 69
Safety and warnings 69
Tools required 69
Parts and materials required 69
Remove 69
Install 73
PowerEdge Replacement Stack Commissioning and Dormant BBR Startup Procedure (Class I and II) 73
Scope 73
Safety and warnings 73
Tools required 74
Parts and materials required 74
Replacing or restarting a stack 74
Service procedures 77
Opening and closing storage tank valves 77
Scope 77
Safety and warnings 77
Tools required 77
Open and close storage tank solenoid valves 77
Draining and filling coolant 79
Scope 79
Safety and warnings 79
Tools required 79
Drain coolant 79
Refill coolant 80
Draining and filling coolant (systems with vented stack) 82
Scope 82
Safety and warnings 82
Tools required 82
Tools required 83
Procedure 83
Cleaning 89
Replacing the air filter 90
Scope 90
Safety and warnings 90
Parts and materials required 90
Remove 90
Install 91
Replacing the coolant filter (fuel cell systems up to and including S/N A2D1S01500R) 92
Scope 92
Safety and warnings 92
Tools required 92
Parts and materials required 92
Remove 92
Install 93
Replacing the coolant filter (fuel cell systems S/N A2D1S01501R and after) 94
Scope 94
Safety and warnings 94
Tools required 94
Parts and materials required 94
Remove 94
Install 95
Replacing the wicking filter 96
Scope 96
Safety and warnings 96
Parts and materials required 96
Remove 96
Install 97
Removing and installing the radiator 98
Scope 98
Safety and warnings 98
Tools required 98
Remove 98
Clean 100
Install 100
Replacing the DPS (fuel cell systems up to and including S/N A2D1S01500R) 101
Scope 101
Safety and warnings 101
Parts and materials required 101
Remove 101
Install 102
Replacing the DPS (fuel cell systems S/N A2D1S01501R and after) 102
Scope 102
Safety and warnings 102
Parts and materials required 102
Remove 103
Adjust the DPS 103
Install 103
Replacing the air compressor (fuel cell systems up to and including S/NA2D1S01500R) 104
Scope 104
Safety and warnings 104
Tools required 104
Prepare 104
Remove 104
Install 109
Replacing the air compressor (fuel cell systems S/N A2D1S01501R and after) 110
Scope 110
Safety and warnings 110
Tools required 111
Prepare 111
Remove 111
Install 114
Replacing the main fan relay 115
Scope 115
Safety and warnings 115
Tools required 115
Prepare 115
Remove 116
Install 117
Replacing the humidifier bypass valve 119
Scope 119
Safety and warnings 119
Tools required 119
Prepare 119
Remove 119
Install 121
Replacing the trican sensor 122
Scope 122
Safety and warnings 122
Tools required 122
Prepare 122
Remove 122
Install 123
Replacing the three-way valve (fuel cell systems up to and including S/N A2D1S01500R) 124
Scope 124
Tools required 124
Parts/Materials required 124
Prepare 124
Remove 124
Install 125
Replacing the three-way valve (fuel cell systems S/N A2D1S01501R and after) 126
Scope 126
Tools required 126
Parts/Materials required 126
Prepare 126
Remove 126
Install 127
Replacing the water level sensor 129
Scope 129
Safety and warnings 129
Tools required 129
Prepare 129
Remove 129
Install 130
Replacing the fuel cell stack 131
Scope 131
Safety and warnings 131
Tools required 131
Parts and materials required 131
Prepare 131
Remove 131
Install 135
Replacing the humidifier 136
Scope 136
Safety and warnings 136
Tools required 136
Prepare 137
Remove 137
Install 139
Replacing thermocouples (TT304 and TT351) 140
Scope 140
Safety and warnings 140
Parts and materials required 140
Remove 140
Install 141
Replacing pressure switch (PS104) or pressure transducer (PT157) 141
Scope 141
Safety and warnings 142
Parts and materials required 142
Remove 142
Install 143
Replacing fuses (F02, F05, F06) 144
Scope 144
Safety and warnings 144
Tools required 144
Remove fuses from the fuse box 144
Install fuses into the fuse box 145
Replacing relays (K06 and K14) 146
Scope 146
Safety and warnings 146
Tools required 146
Remove relays 146
Install relays 147
Replacing and recharging the 24 Volt battery system 148
Scope 148
Safety and warnings 148
Tools required 148
Parts and materials required 148
Recharge 148
Remove 149
Install 149
Storing the Lithium-ion batteries 150
Replacing drain valve (XV154) and purge valve (XV155) 152
Scope 152
Safety and warnings 152
Tools required 152
Remove 152
Install 153
Replacing the ejector (PCE103) 154
Scope 154
Safety and warnings 154
Tools required 154
Parts and materials required 154
Prepare 154
Remove 154
Install 157
Replacing the ultracapacitor module 160
Scope 160
Safety and warnings 160
Tools required 160
Parts and material required 160
Prepare 160
Remove 161
Install 164
Replacing the DC/DC unit 165
Scope 165
Safety and warnings 165
Tools required 165
Remove 165
Install 168
Replacing the motor controller 169
Scope 169
Safety and warnings 169
Tools required 169
Parts and materials required 169
Prepare 169
Remove 169
Install 170
Replacing the CVM 172
Scope 172
Safety and warnings 172
Tools required 172
Prepare 172
Remove 172
Install 174
Replacing the VSM 175
Scope 175
Safety and warnings 175
Tools required 175
Prepare 175
Remove 175
Install 176
Replacing the heater relay 177
Scope 177
Safety and warnings 177
Tools required 177
Remove 177
Install 178
Replacing solenoid valve (XV101) 179
Scope 179
Safety and warnings 179
Tools required 179
Remove 179
Install 181
Replacing FL190, PCV192 and PCV193 182
Scope 182
Safety and warnings 182
Tools required 182
Remove 182
Install 184
Replacing FV194 and OR198 185
Scope 185
Safety and warnings 185
Tools required 185
Remove 185
Install 187
Replacing the vent OK or watchdog timer (fuel cell systems up to and including S/N A2D1S01500R) 187
Scope 187
Safety and warnings 187
Tools required 187
Prepare 187
Remove 188
Install 188
Replacing the vent OK or watchdog timer (fuel cell systems S/N A2D1S01501R and after) 189
Scope 189
Safety and warnings 189
Tools required 189
Prepare 189
Remove 189
Install 190
Periodic maintenance procedures 192
Periodic maintenance procedures 192
Safety Performance Checks 192
Special Tools 193
Special tools 193