Yale Forklift C1000V48 C1100V48 (A2D4) Service Manual

Description

List of Files:
31010724-31010724-(01-2023) Fuel Cell System.pdf (180 Pages):
Safety information
General hazards, warnings, and cautionary statements
Hydrogen-specific concerns
Safety label symbols description
Swagelok® procedures
Removing and installing the cover panels
Disconnecting the batteries
H2 pressure relief
Leak check high pressure plumbing
Updating the firmware
Replacing the air filter
Replacing the DI filter
Drain and fill coolant
Replacing the main battery
Replacing the 12V battery
Replacing the DC/DC assembly
Replacing the main electrical box
Replacing the 24V DCDC
Replacing the main PCB and system controller (STW)
Replacing the data port
Replacing the start button
Replacing the emergency stop button
Replacing the E-Stop contact block
Replacing the power cables
Replacing the hydrogen leak sensors
Replacing the air compressor
Replacing the air compressor motor controller
Replacing the coolant pump
Replacing the coolant filter
Replacing the truck contactor
Replacing the battery contactor
Replacing the DC/DC contactor
Replacing the fuel cell stack contactor
Replacing the current transducer
Replacing the pre-charge resistor
Replacing the fuses
Replacing the humidifier
Replacing the hydrogen fill line
Replacing the hydrogen fill port
Replacing the hydrogen fuel tank
Replacing the hydrogen regulator
Replacing the hydrogen recirculation pump
Replacing the hydrogen purge valve
Replacing the hydrogen pressure sensors
Replacing the coolant thermistor and pressure sensors
Replacing the cathode Mass Air Flow (MAF) sensor
Replacing the cathode temperature and pressure (TMAP)
Replacing the dewatering connector
Replacing the antenna
Replacing the radiator
Replacing the fuel cell stack
Replacing the hydrogen knockout
Replacing the water reservoir
Storage
Commissioning the Nuvera® fuel cell system after storage
Periodic maintenance procedure schedule
Replace the battery filter
Clean and inspect radiator
Inspect the emergency stop button
Coolant maintenance and filtration
Visual coolant check
Coolant conductivity check
Inspect the battery air intake
31010725-31010725-(11-2022) Fuel Cell System-Installation.pdf (42 Pages):
Safety information
Hydrogen-specific concerns
General hazards, warnings, and cautionary statements
Introduction
Components of the Nuvera® Fuel Cell System
Removing the fuel cell system
Required procedures prior to installation
Installing the fuel cell system
Post installation inspection
31010726-31010726-(11-2022) Diagnostic Troubleshooting Manual.pdf (106 Pages):
DTC 516112-31 (0x7E010h)-Battery contactor, close
DTC 516113-17 (0x7E011h)-Battery SOC low
DTC 516113-18 (0x7E011h)-Battery SOC low
DTC 516113-1 (0x7E011h)-Battery SOC critically low
DTC 516113-0 (0x7E011h)-Battery SOC critically high
DTC 516113-16 (0x7E011h)-Battery SOC high
DTC 516114-0 (0x7E012h)-Battery cell voltage critically high
DTC 516114-1 (0x7E012h)-Battery cell voltage critically low
DTC 516114-16 (0x7E012h)-Battery cell voltage high
DTC 516114-18 (0x7E012h)-Battery cell voltage low
DTC 516115-0 (0x7E013h)-Battery cell temperature critically high
DTC 516115-16 (0x7E013h)-Battery cell temperature high
DTC 516115-15 (0x7E013h)-Battery cell temperature moderately high
DTC 516115-18 (0x7E013h)-Battery cell temperature low
DTC 516115-1 (0x7E013h)-Battery cell temperature critically low
DTC 516116-31 (0x7E014h)-BMS fault
DTC 516117-31 (0x7E015h)-BMS Communication error
DTC 516128-1 (0x7E020)-Tank pressure critically low
DTC 516128-18 (0x7E020)-Tank pressure low
DTC 516145-0 (0x7E031)-FCS stack, anode pressure critically high
DTC 516145-16 (0x7E031)-FCS stack, anode pressure high
DTC 516145-1 (0x7E031)-FCS stack, anode pressure critically low
DTC 516145-18 (0x7E031)-FCS stack, anode pressure low
DTC 516146-31 (0x7E032)-DCDC Converter, Current mismatch error
DTC 516147-31 (0x7E033)-DCDC Converter, Communication error
DTC 516148-31 (0x7E034)-DCDC Converter, Forward enable fault
DTC 516149-0 (0x7E035)-FCS Stack temperature critically high
DTC 516149-16 (0x7E035)-FCS Stack temperature high
DTC 516150-0 (0x7E036)-FCS Stack cell voltage critically high
DTC 516150-16 (0x7E036)-FCS Stack cell voltage high
DTC 516150-1 (0x7E036)-FCS Stack cell voltage critically low
DTC 516150-18 (0x7E036)-FCS Stack cell voltage low
DTC 516152-1 (0x7E038)-FCS Stack Coolant pressure critically low
DTC 516152-18 (0x7E038)-FCS Stack Coolant pressure low
DTC 516176-31 (0x7E050)-Coolant system, pump controller communication error
DTC 516177-4 (0x7E051)-Coolant system, Stack inlet temp. voltage low or shorted to ground
DTC 516177-3 (0x7E051)-Coolant system, Stack inlet temp. voltage high or shorted to high source
DTC 516178-4 (0x7E052)-Coolant system, Stack outlet temp. voltage low or shorted to ground
DTC 516178-3 (0x7E052)-Coolant system, Stack outlet temp. voltage high or shorted to high source
DTC 516192-31 (0x7E060)-Cathode system, compressor controller communication error
DTC 516193-31 (0x7E061)-Cathode system, flow measurement error
DTC 516096-31 (0x7E000)-E-stop active
DTC 516097-31 (0x7E001)-Distributed IO, Communication error
DTC 516098-0 (0x7E002) or 516100-0(0x7E004)-LFL critically high
DTC 516098-16 (0x7E002) or 516100-16 (0x7E004)-LFL high
DTC 516098-15 (0x7E002) or 516100-15 (0x7E004)-LFL above normal range
DTC 516098-3 (0x7E002) or 516100-3 (0x7E004)-LFL high or shorted to high source
DTC 516098-4 (0x7E002) or 516100-4 (0x7E004)-LFL low or shorted to low source
DTC 516098-12 (0x7E002) or 516100-12 (0x7E004)-LFL Bad intelligent device or component
DTC 516098-14 (0x7E002) or 516100-14 (0x7E004)-Special instructions
FCS will not turn on
FCS On, No DTC-No voltage from the main contactor
FCS is on, Fuel gauge does not function properly
FCS does not transmit data
Excessive noise
Odor/Smoke/Sparks/Flame
Fluids leaking from FCS