Nuvera C95A-33 Fuel Cell System A2D1 Series Repair Manual

Repair Manual for Hyster A2D1 Series, Models: C95A-33
English

Hyster A2D1 Series, Models: C95A-33 Manual Table Of Content:

-General Information
Safety Information
General Hazards, Warnings, And Cautionary Statements
Hydrogen-Specific Concerns
-Swagelok Fitting Procedures
Swagelok Procedures
-Preparing For Service And Maintenance
Components Of The Nuvera Fuel Cell System
Required Procedures Prior To Service
Preparing The Truck And Removing The Fuel Cell
Preparing The Nuvera Fuel Cell System For Service
Discharging And Recharging The Ultracapacitors
Removing And Installing The Main Cover
Working With Charged Ultracapacitors With Cover Removed
Leak Check Coolant And Anode Loop
Vent Hydrogen From Engine Plumbing Lines
Revert To Normal Ultracaps Connection
Set Up For External Supply Of Nominal Bus Voltage
Installing Vector Vn1610 Drivers
Retrieving Data From Vector Data-Logger
Programming The Vsm
Set Up Flags For Vsm Software 3.0.0
Start Into Off Mode
-Service Procedures
Opening And Closing Storage Tank Valves
Draining And Filling Coolant
Draining And Filling Coolant (Systems With Vented Stack)
Replacing The Air Filter
Replacing The Coolant Filter
Replacing The Wicking Filter
Removing And Installing The Engine Sled
Removing And Installing The Radiator
Replacing The Dps (Fuel Cell Systems Up To And Including S/N A2D2S01500R)
Replacing The Dps (Fuel Cell Systems S/N A2D2S01501R And After)
Replacing The Air Compressor (Fuel Cell Systems Up To And Including S/N A2D2S01500R)
Replacing The Air Compressor (Fuel Cell Systems S/N A2D2S01501R And After)
Replacing The Main Fan Relay
Replacing The Humidifier Valve
Replacing The Trican Sensor
Replacing The Three-Way Valve (Fuel Cell Systems Up To And Including S/N A2D2S01500R)
Replacing The Three-Way Valve (Fuel Cell Systems S/N A2D2S01501R And After)
Replacing The Water Level Sensor
Replacing The Fuel Cell Stack
Replacing The Humidifier
Replacing Thermocouples (Tt304 And Tt351)
Replacing Fuses (F02, F05, F06)
Replacing Relays (K06 And K14)
Recharging 24 Volt Battery System
Replacing Drain Valve (Xv154) And Purge Valve (Xv155)
Replacing The Ejector (Pce103)
Replacing The Ultracapacitor Module
Replacing The Dc/Dc Unit
Replacing The Motor Controller
Replacing The Cvm
Replacing The Vsm
Replacing The Heater Relay
Replacing The Solenoid Valve (Xv101)
Replacing Fl190, Pcv192 And Pcv193
Replacing Fv194 And Or198
Replacing The Vent Ok And Watchdog Timers (Fuel Cell Systems Up To And Including S/N A2D2S01500R)
Replacing The Vent Ok And Watchdog Timers (Fuel Cell Systems S/N A2D2S01501R And After)
-Periodic Maintenance Procedures
Periodic Maintenance Procedures
-Special Tools
Special Tools

The Service Repair Manual provide general guidelines for maintenance and service of the A2D1 Series, Models: C95A-33 and are intended for use by trained and experienced technicians. Failure to properly maintain equipment or to follow instructions contained in the Service Manual could result in damage to the products, personal injury, property damage or death.

When lifting parts or assemblies, make sure all slings, chains, or cables are correctly fastened, and that the load being lifted is balanced. Make sure the crane, cables, and chains have the capacity to support the weight of the load.

Do not lift heavy parts by hand, use a lifting mechanism.
Wear safety glasses.
DISCONNECT THE BATTERY CONNECTOR before doing any maintenance or repair on electric lift trucks. Disconnect the battery ground cable on internal combustion lift trucks.
Always use correct blocks to prevent the unit from rolling or falling. See HOW TO PUT THE LIFT TRUCK ON BLOCKS in the Operating Manual or the Periodic Maintenance section.
Caution:
Always fasten a DO NOT OPERATE tag to the controls of the unit when making repairs, or if the unit needs repairs.
Be sure to follow the WARNING and CAUTION notes in the instructions.
Gasoline, Liquid Petroleum Gas (LPG), Compressed Natural Gas (CNG), and Diesel fuel are flammable.
Be sure to follow the necessary safety precautions when handling these fuels and when working on these fuel systems.
Batteries generate flammable gas when they are being charged. Keep fire and sparks away from the area. Make sure the area is well ventilated.