P54.33-A000-09
Shown on instrument cluster with view of kilometer reading in the multifunction display (30) |
4 | Drive system readiness to drive | 22 | Drive system | |
18 | Fuel level indicator | 23 | Hydrogen alarm | |
19 | Fuel reserve with fuel filler cap position indicator | 30 | Multifunction display | |
21 | Electrical fault |
P47.60-A032-09
31 | Supporting frame | 6 | Gas cylinder above rear axle | |
5 | Gas cylinder in transmission tunnel |
Shown here is inspection station at front end of gas cylinder in transmission tunnel |
3 | Inspection station at front and rear ends of gas cylinder |
40 | Gas detector |
P47.60-A037-03
22 | Bubble forming |
P47.60-A031-02
P06.40-2043-09
2 | Replace hydrogen sensor 2 on fuel tank above rear axle |
Danger | Risk of explosion caused by escaping hydrogen or overheating of the fuel tanks when working on the hydrogen system. Risk of frostbite to body parts caused by escaping gas and by touching component parts carrying gas when emptying fuel tanks. Risk of asphyxiation caused by inhalation of air diluted by hydrogen. Risk of burn injuries by coming into contact with an invisible pale blue hydrogen flame. | ||
Danger | Risk of death when working on component parts and systems with U >= 30 V alternating voltage (AC) or U >= 60 V direct voltage (DC) | Do not touch damaged or defective live component parts and lines or non-insulated electrical connections and lines. | |
Topical note | Notes on fuel cell system | ||
Topical note | General information on handling vehicles with high-voltage on-board electrical system and/or lithium-ion battery and/or gaseous-fuel drive system | ||
| Check | ||
1 | Switch on ignition and check whether the fuel level indicator (18) in the instrument cluster displays > 50 % fill level. | If the fuel level indicator (18) in the instrument cluster displays < 50 % fill level, | |
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refuel vehicle until the fuel level indicator (18) in the instrument cluster displays > 50 % fill level. | |||
After obtaining special order. | |||
2 | Start vehicle and check whether faults relevant to the fuel cell system are present. | The drive system readiness to drive (4) "READY" must be displayed in the instrument cluster. | |
If faults relevant to the fuel cell system are displayed in the multifunction display (30), electrical fault (21), drive system (22) or hydrogen alarm (23) or the fuel reserve with fuel filler cap position indicator (19) is displayed or the drive system readiness to drive (4) does not display "READY", | |||
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determine cause and rectify fault. | |||
After obtaining special order. | |||
3 | Switch off ignition. | ||
| Remove | ||
4 | Remove underfloor paneling above the gas cylinder in the transmission tunnel (5) and the gas cylinder above the rear axle (6). | ||
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| Check | ||
5 | Check the manufacturing date of the gas cylinders. | ||
6 | Check gas cylinder in transmission tunnel (5) for damage and compare with damage profiles. | ||
If necessary, use commercially available devices/tools. Explosion-proof flashlight, comparable to AccuLux flashlight MHL 5 EX from Witte + Sutor GmbH. | |||
If necessary, use commercially available devices/tools. Swiveling inspection mirror. | |||
Use safety glasses and protective gloves. | |||
If the gas cylinder in the transmission tunnel (5) exhibits damage that makes replacement necessary, | |||
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replace the gas cylinder in the transmission tunnel (5). | |||
After obtaining special order. | |||
7 | Check the gas cylinder above the rear axle (6) for damage and compare with damage profiles. | ||
If necessary, use commercially available devices/tools. Explosion-proof flashlight, comparable to AccuLux flashlight MHL 5 EX from Witte + Sutor GmbH. | |||
If necessary, use commercially available devices/tools. Swiveling inspection mirror. | |||
Use safety glasses and protective gloves. | |||
If the gas cylinder above the rear axle (6) exhibits damage that makes replacement necessary, | |||
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replace the gas cylinder above the rear axle (6). | |||
After obtaining special order. | |||
8 | Check test points at front and rear at ends of gas cylinder (3) of the gas cylinder in the transmission tunnel (5) using the gas detection unit (40) 10 - 30 s. | The last filling must be > 30 minutes back. | |
| 000 588 03 21 00 Gas detector | ||
If necessary, use commercially available devices/tools. Explosion-proof flashlight, comparable to AccuLux flashlight MHL 5 EX from Witte + Sutor GmbH. | |||
If necessary, use commercially available devices/tools. Swiveling inspection mirror. | |||
Use safety glasses and protective gloves. | |||
If the value at the test points is < 100 ppm, | |||
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the gas cylinder in the transmission tunnel (5) is tight. | |||
If the value at the test points is > 100 ppm, | |||
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further test measures are required, continue with operation step 6. | |||
9 | Spray the test points of the gas cylinder in the transmission tunnel (5) at which a value of > 100 ppm was displayed, with Snoop leak-detector fluid and observe the degree of bubble forming (22). | The last filling must be > 30 minutes back. | |
Discharge rates on the gas cylinder itself in the transmission tunnel (5) of a max. of 3.6 cm3/min are permitted because of H2 permeation. | |||
Use safety glasses and protective gloves. | |||
The specified guideline value here is 2030 bubbles per minute with Ø 1.5 mm or 32 bubbles per minute with Ø 6 mm. | |||
Snoop Leak detection fluid | |||
If the guideline values are dropped below, | |||
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the gas cylinder in the transmission tunnel (5) is tight. No further checks are required. | |||
If the guideline values are exceeded, | |||
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if the gas cylinder in the transmission tunnel (5) is leaky, replace the gas cylinder in the transmission tunnel (5). | |||
After obtaining special order. | |||
10 | Check test points at front and rear at ends of gas cylinder (3) of the gas cylinder above the rear axle (6) using the gas detection unit (40) 10 - 30 s. | The last filling must be > 30 minutes back. | |
| 000 588 03 21 00 Gas detector | ||
If necessary, use commercially available devices/tools. Explosion-proof flashlight, comparable to AccuLux flashlight MHL 5 EX from Witte + Sutor GmbH. | |||
If necessary, use commercially available devices/tools. Swiveling inspection mirror. | |||
Use safety glasses and protective gloves. | |||
If the value at the test points is < 100 ppm, | |||
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the gas cylinder above the rear axle (6) is tight. | |||
If the value at the test points is > 100 ppm, | |||
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further test measures are required, continue with operation step 8. | |||
11 | Spray the test points of the gas cylinder above the rear axle (6) at which a value of > 100 ppm was displayed, with Snoop leak-detector fluid and observe the degree of bubble forming (22). | The last filling must be > 30 minutes back. | |
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Use safety glasses and protective gloves. | |||
Discharge rates directly above the rear axle (6) of max. 3.6 cm3/min are permitted because of H2-permeation. | |||
The specified guideline value here is 2030 bubbles per minute with Ø 1.5 mm or 32 bubbles per minute with Ø 6 mm. | |||
Snoop Leak detection fluid | |||
If the guideline values are dropped below, | |||
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the gas cylinder above the rear axle (6) is tight. No further checks are required. | |||
If the guideline values are exceeded, | |||
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the gas cylinder above the rear axle (6) is leaky, then replace the gas cylinder above the rear axle (6). | |||
After obtaining special order. | |||
12 | Check condition of valves at ends of gas cylinder in the transmission tunnel (5) and the gas cylinder above the rear axle (6) and check also for external leak tightness. | ||
Use safety glasses and protective gloves. | |||
13 | Check the supporting frame (31) for cracks, deformation, corrosion, and check for tight fit by firmly pushing and pulling it. | Use safety glasses and protective gloves. | |
If problems occur, | |||
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rectify the problems. | |||
After obtaining special order. | |||
14 | Check that the gas cylinder in the transmission tunnel (5) and the gas cylinder above the rear axle (6) are firmly seated in the supporting frame (31). | Use safety glasses and protective gloves. | |
If problems occur, | |||
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rectify the problems. | |||
After obtaining special order. |