2 | Filler neck |
P06.00-A005-05
3 | Bleed valve in valve unit |
4 | Red O-ring |
P06.00-A020-03
P47.60-A020-09
MV | Manual valve |
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. | ||
Topical note | Notes on fuel cell system | ||
Notes on safety-relevant components | |||
Inert | |||
1 | Empty fuel tanks, including line system with the diagnostic device, to 2 bar hydrogen. | ||
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To do this, select the following menu item: | |||
2 | Fill fuel tanks incl. line system via the filler neck (2) with 40 bar nitrogen. | ||
| 000 588 09 21 00 Leak tester | ||
Commercially available devices/tools explosion-proof flashlight, comparable with AccuLux flashlight MHL 5 EX of the company Witte + Sutor GmbH. | |||
It is necessary for the tank temperature to be in the range of 5 to 35 °C before the start. | |||
Use commercially available nitrogen bottle bundles. | |||
Pressure monitoring is carried out visually via the manometer on the nitrogen bottle. | |||
3 | Relieve pressure in the filling nozzle and detach filling nozzle. | ||
| 000 588 09 21 00 Leak tester | ||
Commercially available devices/tools explosion-proof flashlight, comparable with AccuLux flashlight MHL 5 EX of the company Witte + Sutor GmbH. | |||
4 | Seal filler neck (2) with the suitable dust cap for the vehicle. | Commercially available devices/tools explosion-proof flashlight, comparable with AccuLux flashlight MHL 5 EX of the company Witte + Sutor GmbH. | |
5 | Empty fuel tanks, including line system with the diagnostic device, to 2 bar hydrogennitrogen mixture. | ||
| |||
To do this, select the following menu item: | |||
6 | Fill fuel tanks, incl. line system, again via the filler neck, (2) with 40 bar nitrogen. | ||
| 000 588 09 21 00 Leak tester | ||
Commercially available devices/tools explosion-proof flashlight, comparable with AccuLux flashlight MHL 5 EX of the company Witte + Sutor GmbH. | |||
It is necessary for the tank temperature to be in the range of 5 to 35 °C before the start. | |||
Use commercially available nitrogen bottle bundles. | |||
Pressure monitoring is carried out visually via the manometer on the nitrogen bottle. | |||
7 | Relieve pressure in the filling nozzle and detach filling nozzle. | ||
| 000 588 09 21 00 Leak tester | ||
Commercially available devices/tools explosion-proof flashlight, comparable with AccuLux flashlight MHL 5 EX of the company Witte + Sutor GmbH. | |||
8 | Seal filler neck (2) with the suitable dust cap for the vehicle. | Commercially available devices/tools explosion-proof flashlight, comparable with AccuLux flashlight MHL 5 EX of the company Witte + Sutor GmbH. | |
9 | Empty fuel tanks, including line system with the diagnostic device, to less than 2 bar nitrogen. | ||
| Connect STAR DIAGNOSIS and read out fault memory | ||
To do this, select the following menu item: | |||
10 | Lift vehicle at the front, secure, and remove underfloor paneling of the inerted fuel tank. | If the pressure in the fuel tank > 2 bar nitrogen after emptying. | |
Commercially available devices/tools explosion-proof flashlight, comparable with AccuLux flashlight MHL 5 EX of the company Witte + Sutor GmbH. | |||
Use commercially available hydraulic vehicle jack or wheel-engaging lift. | |||
11 | Remove red O-ring (4) from the square of the bleed valve in the valve unit (3) on the inerted fuel tank and keep safe. | If the pressure in the fuel tank > 2 bar nitrogen after emptying. | |
Commercially available devices/tools explosion-proof flashlight, comparable with AccuLux flashlight MHL 5 EX of the company Witte + Sutor GmbH. | |||
12 | Slowly open the bleed valve in valve unit (3) on the inerted fuel tank and then turn back by revolution. | If the pressure in the fuel tank > 2 bar nitrogen after emptying. | |
Commercially available devices/tools explosion-proof flashlight, comparable with AccuLux flashlight MHL 5 EX of the company Witte + Sutor GmbH. | |||
Use commercially available tools. | |||
13 | Actuate/open pressure regulating unit in steps with the diagnostic device until the pressure in the fuel tank is approx. 1.75 bar. | If the pressure in the fuel tank > 2 bar nitrogen after emptying. | |
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To do this, select the following menu item: | |||
Total duration approx. 60 s. | |||
14 | Slowly close bleed valve in the valve unit (3) on the inerted fuel tank. | If the pressure in the fuel tank > 2 bar nitrogen after emptying. | |
Commercially available devices/tools explosion-proof flashlight, comparable with AccuLux flashlight MHL 5 EX of the company Witte + Sutor GmbH. | |||
Torque for sealing of bleed valve in valve unit | |||
15 | Attach red O-ring (4) again to the square of the bleed valve in the valve unit (3) on the inerted fuel tank. | If the pressure in the fuel tank > 2 bar nitrogen after emptying. | |
Commercially available devices/tools explosion-proof flashlight, comparable with AccuLux flashlight MHL 5 EX of the company Witte + Sutor GmbH. | |||
16 | Seal manual valve (MV) on the inerted fuel tank. | Commercially available devices/tools explosion-proof flashlight, comparable with AccuLux flashlight MHL 5 EX of the company Witte + Sutor GmbH. | |
The manual valves (MV) have a hexagon head with a wrench size of 7 mm. | |||
Torque for sealing of manual valve in valve unit | |||
17 | Park vehicle on the wheels. | If the pressure in the fuel tank > 2 bar nitrogen after emptying. | |
Commercially available devices/tools explosion-proof flashlight, comparable with AccuLux flashlight MHL 5 EX of the company Witte + Sutor GmbH. |