HYDROGEN TANK ASSEMBLY DISCHARGE COMPRESSED HYDROGEN GAS

CAUTION / NOTICE / HINT

Tech Tips

These procedures are only performed when discharging compressed hydrogen gas from the hydrogen tank assemblies.

CAUTION:


  • B006JCO

    When discharging pressurized hydrogen gas from the from the hydrogen tank assembly, do not perform the procedure in an indoor area with poor ventilation.

  • Accumulated hydrogen gas could ignite, resulting in a serious accident.


  • B006JFPC15
    *a When inside of piping is pressurized

    Do not install or remove any hydrogen system components without first performing depressurization procedures.

  • The highly pressurized hydrogen gas inside the hydrogen tank assembly could blow out, resulting in a serious accident.


  • B006JLTC20
    *a Manual Valve Open

    Do not perform depressurization procedures when the manual valve of the hydrogen tank assembly is open.

  • The highly pressurized hydrogen gas inside the hydrogen tank assembly could blow out, resulting in a serious accident.


  • B006JBL

    When performing depressurization, do not perform procedures by hand without wearing protective glasses and gloves.

  • The highly pressurized hydrogen gas inside the hydrogen tank assembly could blow out, resulting in a serious accident.


  • B006JLX

    While discharging pressurized hydrogen gas, the temperature inside the tank decreases and frost may form on the outside. Do not touch tanks, piping, or SST (hydrogen venting tool) when frost has formed on them.

  • Touching tanks, piping, or SST (hydrogen venting tool) on which frost has formed could result in burn-like injuries due to frostbite.


  • B006JJM

    When opening the tank shut valve and applying pressure to the SST (hydrogen venting tool), stay away from the SST (flexible hose).

  • If the SST (flexible hose) comes off, you could be struck by the loose end of the SST (flexible hose), causing a serious accident.

Note


  • After turning the power switch off, waiting time may be required before disconnecting the cable from the negative (-) auxiliary battery terminal. Therefore, make sure to read the disconnecting the cable from the negative (-) auxiliary battery terminal notices before proceeding with work.

    Click here

  • When performing depressurization, do not open or close any parts of the hydrogen gas piping except for the following:

    - Adjustment bolt of the hydrogen tank assembly manual valve

    - Tank shut valve of the hydrogen tank assembly

    - No. 1 hydrogen supply regulator plug

  • Place signs [HIGH PRESSURE GAS WORK IN PROGRESS - DO NOT TOUCH!], etc. to warn other technicians to be cautious. (An example sign is included, so make a copy and use it.)

    B006JJCE02
    *1 Place signs [HIGH PRESSURE GAS WORK IN PROGRESS - DO NOT TOUCH!], etc. to warn other technicians to be cautious. (An example sign is included, so make a copy and use it.)

PROCEDURE


  1. CHECK DTC OUTPUT


    1. Check for DTCs.

      Click here

      Note

      If DTCs are output, perform troubleshooting for each DTC.

  2. REMOVE FRONT FLOOR CENTER COVER LH

    Click here

  3. REMOVE FRONT FLOOR CENTER COVER RH

    Click here

  4. REMOVE NO. 2 FLOOR UNDER COVER

    Click here

  5. REMOVE NO. 1 FLOOR UNDER COVER

    Click here

  6. PREPARE SST (HYDROGEN VENTING TOOL)

    Tech Tips

    Before performing work, check the set up conditions of the SST (hydrogen venting tool).

    Figure 1. <Hydrogen Gas Discharging Conditions>

    B006JMFC02
    *a Basic Conditions *b Other than Basic Conditions (if mechanism cannot be set up outdoors)

    1. Check the assembly of the SST (hydrogen venting tool).

      B006JJEC03
      *a SST (Venting Stand) *b SST (Flexible Hose)
      *c SST (Upper Release Pipe) *d SST (Middle Release Pipe)
      *e SST (Lower Release Pipe) *f Open/close Valve
      *g Pressure Gauge *h Discharge Pipe Support
      *i SST (O Ring (Replace at time of using SST (hydrogen venting tool))) - -
      SST
      09404-62010   ( 09404-06010, 09404-06020, 09404-06030, 09404-06040, 09404-06050, 09404-06060 )

    2. Make sure to replace the SST (3 O-rings) of the SST (hydrogen venting tool) with new ones.


      1. B006JH4C01
        *a SST (O-ring)
        *b SST (Middle Release Pipe)

        Remove the SST (O-ring) from the SST (middle release pipe).

        SST
        09404-62010   ( 09404-06060, 09404-06040 )

      2. Install a new SST (O-ring) to the SST (middle release pipe).

        SST
        09404-62010   ( 09404-06040, 09404-06060 )
      3. B006JJOC01
        *a SST (O-ring)
        *b SST (Lower Release Pipe)

        Remove the SST (O-ring) from the SST (lower release pipe).

        SST
        09404-62010   ( 09404-06050, 09404-06060 )

      4. Install a new SST (O-ring) to the SST (lower release pipe).

        SST
        09404-62010   ( 09404-06050, 09404-06060 )
      5. B006JFFC03
        *a SST (O-ring)
        *b Protective Tape

        Using a thin-bladed screwdriver with its tip wrapped in protective tape, remove the SST (O-ring) from the release pipe support.

        SST
        09404-62010   ( 09404-06010, 09404-06060 )
      6. B006JELC03
        *a SST (O-ring)
        *b Release Pipe Support
        *c Collar

        As shown in the illustration, install a new SST (O-ring) to the release pipe support.

        SST
        09404-62010   ( 09404-06060 )

    3. Connect each part of the SST (hydrogen venting tool) and prepare it for use.


      1. B006JEMC03
        *a SST (Upper Release Pipe)
        *b SST (Middle Release Pipe)
        *c SST (O-ring)
        *d Thickness Gauge
        *e 1.7 mm (0.0669 in.)

        Connect the SST (upper release pipe) and SST (middle release pipe), and using a thickness gauge, measure the clearance in the location shown in the illustration.

        SST
        09404-62010   ( 09404-06030, 09404-06040, 09404-06060 )
        Discharge pipe connection clearance
        1.7 mm (0.0669 in.)

        Note

        Perform the procedure by hand. Do not use any tools.

      2. B006JIUC03
        *1 SST (Middle Release Pipe)
        *2 SST (Lower Release Pipe)
        *a SST (O-ring)
        *b Thickness Gauge
        *c 1.7 mm (0.0669 in.)

        Connect the SST (middle release pipe) and SST (lower release pipe), and using a thickness gauge, measure the clearance in the location shown in the illustration.

        SST
        09404-62010   ( 09404-06040, 09404-06050, 09404-06060 )
        Discharge pipe connection clearance
        1.7 mm (0.0669 in.)

        Note

        Perform the procedure by hand. Do not use any tools.

      3. B006JDWC03
        *a SST (Lower Release Pipe)
        *b SST (Variable Open Wrench)
        *c SST Fulcrum Length
        *d Torque Wrench Fulcrum Length

        Connect the SST (lower release pipe) to the release pipe support, and using SST (variable open wrench), tighten the nut.

        SST
        09922-10010
        09404-62010   ( 09404-06050 )
        Torque:
        Specified tightening torque
        20 N*m  { 204 kgf*cm, 15 ft.*lbf }

        Tech Tips


        • Calculate the torque wrench reading when changing the fulcrum length of the torque wrench.

          Click here

        • When using SST (fulcrum length of 136 mm (5.35 in.)) + torque wrench (fulcrum length of 180 mm (7.09 in.)):

          11.4 N*m (116 kgf*cm, 8 ft.*lbf)

      4. B006JEU

        Connect the ground wire.

        Note

        Connect the ground wire to somewhere that will enable secure electrical grounding.

  7. CONNECT SST (HYDROGEN VENTING TOOL)


    1. B006JIOC01
      *a SST (Venting Stand)

      Check that the open/close valve of the SST (venting stand) is closed.

      SST
      09404-62010   ( 09404-06010 )

    2. Remove the 3 bolts and disconnect the FC exhaust pipe.

      B006JD6
    3. B006JFOC03
      *a Adjustment Bolt
      *b Manual Valve Open
      *c Manual Valve Closed
      *d Clockwise

      Using an 8 mm socket hexagon wrench, rotate the adjustment bolt in the clockwise direction to close the manual valve of the No. 1 hydrogen tank assembly.

      Torque:
      20 N*m  { 204 kgf*cm, 15 ft.*lbf }

      Note


      • The manual valve shuts off the pressure from the hydrogen tank assembly, so be careful not to damage the hexagonal portion.

      • If the hexagonal portion has been damaged, the No. 1 hydrogen tank assembly must be replaced.

    4. B006JHUC03
      *a Adjustment Bolt
      *b Manual Valve Open
      *c Manual Valve Closed
      *d Clockwise

      Using an 8 mm socket hexagon wrench, rotate the adjustment bolt in the clockwise direction to close the manual valve of the No. 2 hydrogen tank assembly.

      Torque:
      20 N*m  { 204 kgf*cm, 15 ft.*lbf }

      Note


      • The manual valve shuts off the pressure from the hydrogen tank assembly, so be careful not to damage the hexagonal portion.

      • If the hexagonal portion has been damaged, the No. 2 hydrogen tank assembly must be replaced.

    5. Before beginning depressurization procedures, if there are any contaminants such as mud near the medium pressure leak check port of the hydrogen supply regulator assembly, clean them away.

      Tech Tips

      Performing installation while any foreign matter is adhered to the No. 1 hydrogen supply regulator plug could cause a hydrogen gas leak.

    6. Perform depressurization.


      1. Make sure that the manual valves of the No. 1 hydrogen tank assembly and No. 2 hydrogen tank assembly are closed.

      2. B006JDMC01
        *1 Hydrogen Supply Regulator Union
        *a Body
        *b Paint Mark

        Apply paint marks to the hydrogen supply regulator union and the body of the hydrogen supply regulator assembly as shown in the illustration.

        Tech Tips

        When loosening the No. 1 hydrogen supply regulator plug, there is a possibility that the hydrogen supply regulator union could turn together with it and be loosened, so applying paint marks will enable judgment of whether the hydrogen supply regulator union has been loosened.

      3. B006JL8

        Slowly loosen the No. 1 hydrogen supply regulator plug until the hissing sound of gas escaping can be heard, then stop loosening the No. 1 hydrogen supply regulator plug and wait for the sound to stop. Repeat this procedure multiple times until the sound stops occurring, in order to depressurize the compressed hydrogen gas from the medium pressure leak check port of the hydrogen supply regulator assembly.

        CAUTION:


        • Do not perform depressurization procedures when the manual valve of the hydrogen tank assembly is open.

        • The highly pressurized hydrogen gas inside the hydrogen tank assembly could blow out, resulting in a serious accident.

        B006JLTC20
        *a Manual Valve Open

        • B006JBL

          When performing depressurization, do not perform procedures by hand without wearing protective glasses and gloves.

        • The highly pressurized hydrogen gas inside the hydrogen tank assembly could blow out, resulting in a serious accident.

        Note

        When performing depressurization, only loosen the No. 1 hydrogen supply regulator plug. Do not remove it.

    7. B006JKA

      Blow compressed air at the underside of the vehicle to disperse any accumulated hydrogen gas.

    8. Remove the No. 1 hydrogen supply regulator plug from the hydrogen supply regulator union.

      Note

      When frost has formed on the hydrogen tank assembly or piping, water droplets may be formed when the frost begins to melt. If water droplets enter the tank or piping, it could result in blockage of the hydrogen piping, so do not allow water droplets to enter the tank or piping.

    9. B006JK5

      Remove the O-ring from the hydrogen supply regulator union.

    10. B006JHEC01
      *a Protective Tape

      To prevent damage to the seal portions and threaded portions, and to prevent foreign matter such as dust or metal fragments from entering the openings, cover the seal portions, threaded portions, and openings of the hydrogen supply regulator union with protective tape.

    11. B006JG3C01
      *a Correct
      *b Incorrect
      *c Paint Mark

      Check that the hydrogen supply regulator union has not been loosened.

      Tech Tips

      If the hydrogen supply regulator union has been loosened, there is the possibility of a compressed hydrogen gas leak, so it is necessary to remove the hydrogen supply regulator union and replace the O-ring with a new one.

    12. Procedures for when the hydrogen supply regulator union has been loosened:


      1. B006JLS

        Remove the hydrogen supply regulator union.

        Note

        When frost has formed on the hydrogen tank assembly or piping, water droplets may be formed when the frost begins to melt. If water droplets enter the tank or piping, it could result in blockage of the hydrogen piping, so do not allow water droplets to enter the tank or piping.

      2. B006JG8C01
        *a Protective Tape

        To prevent foreign matter such as dust or metal fragments from entering the openings, cover the seal portions, threaded portions, and openings of the hydrogen supply regulator union installation portion with protective tape.

      3. B006JK2

        Remove the O-ring from the hydrogen supply regulator union.

        Note

        Perform the procedure by hand. Do not use any tools.

      4. Clean and degrease the threaded portion of the hydrogen supply regulator union.

      5. B006JIHC01
        *1 Hydrogen Supply Regulator Union
        *a Protective Tape

        To prevent the O-ring from being damaged during installation, apply protective tape as shown in the illustration.

        Tech Tips

        Cover the hydrogen supply regulator union with protective tape so that the threaded portion and the hole cannot be seen.

      6. Coat a new O-ring with TOYOTA Genuine FC Grease.

      7. B006JG4

        Install the O-ring to the hydrogen supply regulator union.

        Note


        • Make sure not to damage the O-ring.

        • Make sure the O-ring is not twisted.

      8. Remove the protective tape from the hydrogen supply regulator union.

        Note

        When frost has formed on the hydrogen tank assembly or piping, water droplets may be formed when the frost begins to melt. If water droplets enter the tank or piping, it could result in blockage of the hydrogen piping, so do not allow water droplets to enter the tank or piping.

      9. B006JJ0

        Coat the O-ring and the threaded portion of the hydrogen supply regulator union with TOYOTA Genuine FC Grease.

      10. To prevent the hydrogen supply regulator union installation portion from being contaminated by dust, metal fragments, etc., do not remove the protective tape from it until immediately before performing the work.

        Note

        When frost has formed on the hydrogen tank assembly or piping, water droplets may be formed when the frost begins to melt. If water droplets enter the tank or piping, it could result in blockage of the hydrogen piping, so do not allow water droplets to enter the tank or piping.

      11. Install the hydrogen supply regulator union.

        Torque:
        41.5 N*m  { 423 kgf*cm, 31 ft.*lbf }

        Note

        When installing the O-ring, make sure that it is not pinched.

    13. To prevent damage to the seal portions and threaded portions, and to prevent foreign matter such as dust or metal fragments from entering the openings, do not remove the protective tape covering the seal portions, threaded portions, and openings of the hydrogen supply regulator union until immediately before performing work.

      Note

      When frost has formed on the hydrogen tank assembly or piping, water droplets may be formed when the frost begins to melt. If water droplets enter the tank or piping, it could result in blockage of the hydrogen piping, so do not allow water droplets to enter the tank or piping.

    14. B006JFS

      Apply TOYOTA Genuine FC Grease to a new O-ring and to the threaded portion of the hydrogen supply regulator union.

    15. Install the O-ring to the hydrogen supply regulator union.

      Note

      During installation, make sure not to damage the O-ring.

    16. Connect the SST (hydrogen venting tool).

      SST
      09404-62010   ( 09404-06010, 09404-06020, 09404-06030, 09404-06040, 09404-06050 )

      1. B006JKCC03
        *a SST (Flexible Hose)
        *b SST (Open End Wrench)
        *c SST Fulcrum Length
        *d Torque Wrench Fulcrum Length

        Using SST (open end wrench), install the SST (flexible hose) to the hydrogen supply regulator union.

        SST
        09922-10240
        09404-62010   ( 09404-06020 )
        Torque:
        Specified tightening torque
        25 N*m  { 255 kgf*cm, 18 ft.*lbf }

        Note


        • Make sure that the SST (flexible hose) does not interfere with any part of the vehicle.

        • If the SST (flexible hose) interferes with any part of the vehicle, protect it with a piece of cloth, etc.

        Tech Tips


        • Calculate the torque wrench reading when changing the fulcrum length of the torque wrench.

          Click here

        • When using SST (fulcrum length of 40 mm (1.57 in.)) + torque wrench (fulcrum length of 255 mm (10.04 in.)):

          21.6 N*m (220 kgf*cm, 16 ft.*lbf)

      2. B006JIAC01
        *a SST (Flexible Hose)
        *b SST (Venting Stand)

        Connect the SST (flexible hose) to the SST (Venting Stand).

        SST
        09404-62010   ( 09404-06010, 09404-06020 )
    17. B006JHS

      Under basic conditions


      1. Set the SST (hydrogen venting tool) in an outdoor location.

        Note

        Take care that the compressed hydrogen gas that is discharged during the discharging procedure does not enter any indoor location.

    18. B006JJQ

      Other than basic conditions (when outdoor setup is not possible)


      1. When the SST (hydrogen venting tool) will be set up indoors, locate it along a wall near a window, and with the tip of the SST (upper release pipe) outdoors.

        Note

        Open windows on two sides or more, and ensure that there is adequate ventilation to prevent the compressed hydrogen gas that is discharged from collecting inside.

    19. Open the tank shut valves of the No. 1 and No. 2 hydrogen tank assemblies, and after 2 to 3 seconds, close the tank shut valves again.

      CAUTION:

      B006JJM

      • When opening the tank shut valve and applying pressure to the SST (hydrogen venting tool), stay away from the SST (flexible hose).

      • If the SST (flexible hose) comes off, you could be struck by the loose end of the SST (flexible hose), causing a serious accident.

      Note

      If the Data List item "Medium-range Hydrogen Pressure (gauge)" decreases to below 0.6 MPa (6.1 kgf/cm2, 87 psi) the tank shut valves of the No. 1 and No. 2 hydrogen tank assemblies will forcibly close.

    20. If the tank shut valves of the No. 1 and No. 2 hydrogen tank assemblies do not open, open the tank shut valves again, and after 2 to 3 seconds, close the tank shut valves.

    21. Perform preliminary leak check (using remaining piping pressure).

      Tech Tips

      Perform leak check using the pressure remaining upstream of the tank shut valve.


      1. If there are any water droplets, etc. adhering to the measurement locations, wipe them away before performing the procedure.

        Note

        Performing the measurement while any water droplets, etc. are adhering could damage the hydrogen gas detector.

      2. Using SST and a hydrogen gas detector, inspect for leaks in the locations shown in the illustration.

        Figure 3. <Locations to Check for Leaks>

        B006JLBC01
        B006JEG Leak Check Location - -
        SST
        09401-62010
        Specified Value
        300 ppm or less

        Note

        If any values are outside the specified range, disconnect those locations that have leaks and assemble the parts again.

    22. B006JDNC04
      *a Adjustment Bolt
      *b Manual Valve Closed
      *c Manual Valve Open
      *d Counterclockwise

      Using an 8 mm socket hexagon wrench, rotate the adjustment bolt counterclockwise, and open the No. 1 hydrogen tank assembly manual valve.

      Note


      • The manual valve shuts off the pressure from the hydrogen tank assembly, so be careful not to damage the hexagonal portion.

      • If the hexagonal portion is damaged, it will be impossible to operate the adjustment bolt.

      • Do not rotate the adjustment bolt more than 4 rotations.

      • Rotating the adjustment bolt more than 4 rotations could damage the manual valve.

      • If the manual valve is damaged, it will be necessary to replace the No. 1 hydrogen tank assembly.

    23. B006JMMC04
      *a Adjustment Bolt
      *b Manual Valve Closed
      *c Manual Valve Open
      *d Counterclockwise

      Using an 8 mm socket hexagon wrench, rotate the adjustment bolt counterclockwise, and open the No. 2 hydrogen tank assembly manual valve.

      Note


      • The manual valve shuts off the pressure from the hydrogen tank assembly, so be careful not to damage the hexagonal portion.

      • If the hexagonal portion is damaged, it will be impossible to operate the adjustment bolt.

      • Do not rotate the adjustment bolt more than 4 rotations.

      • Rotating the adjustment bolt more than 4 rotations could damage the manual valve.

      • If the manual valve is damaged, it will be necessary to replace the No. 2 hydrogen tank assembly.

    24. Open the tank shut valves of the No. 1 and No. 2 hydrogen tank assemblies, and after 2 to 3 seconds, close the tank shut valves again.

      CAUTION:

      B006JJM

      • When opening the tank shut valve and applying pressure to the SST (hydrogen venting tool), stay away from the SST (flexible hose).

      • If the SST (flexible hose) comes off, you could be struck by the loose end of the SST (flexible hose), causing a serious accident.

      Note

      If the Data List item "Medium-range Hydrogen Pressure (gauge)" decreases to below 0.6 MPa (6.1 kgf/cm2, 87 psi) the tank shut valves of the No. 1 and No. 2 hydrogen tank assemblies will forcibly close.

    25. If the tank shut valves of the No. 1 and No. 2 hydrogen tank assemblies do not open, open the tank shut valves again, and after 2 to 3 seconds, close the tank shut valves.

    26. Perform preliminary leak check (using tank pressure)

      Tech Tips

      Perform leak check while applying hydrogen tank pressure.


      1. Using SST and a hydrogen gas detector, inspect for leaks in the locations shown in the illustration.

        Figure 4. <Locations to Check for Leaks>

        B006JLBC01
        B006JEG Leak Check Location - -
        SST
        09401-62010
        Specified Value
        300 ppm or less

        Note


        • If any values are outside the specified range, disconnect those locations that have leaks and assemble the parts again.

        • After reassembling the locations that were leaking, perform the leak check again.

  8. SELECT APPROPRIATE DISCHARGE PROCEDURE

    Note

    Except in a case where the tank shut valve for either the No. 1 or No. 2 hydrogen tank assembly cannot be opened, always perform the discharging procedure for both hydrogen tanks.


    1. Using on-vehicle inspection of the hydrogen tanks or DTC-based troubleshooting, confirm the number of tanks for which compressed hydrogen gas will be discharged, and perform the appropriate discharging procedures.

      Compressed Hydrogen Gas Discharging Conditions
      Number of Compressed Hydrogen Gas Tanks Possible to Discharge Proceed To

      2 Tanks

      (Both No. 1 and No. 2 hydrogen tank assembly tank shut valves can be opened)

      Click here

      1 Tank

      (Either No. 1 or No. 2 hydrogen tank assembly tank shut valve cannot be opened)

      Click here

  9. DRAIN COMPRESSED HYDROGEN GAS (2 Tanks Being Discharged)

    CAUTION:


    • B006JLX

      While discharging pressurized hydrogen gas, the temperature inside the tank decreases and frost may form on the outside. Do not touch tanks, piping, or SST (hydrogen venting tool) when frost has formed on them.

    • Touching tanks, piping, or SST (hydrogen venting tool) on which frost has formed could result in burn-like injuries due to frostbite.

    Note


    • Starting the discharging of compressed hydrogen gas will cause the temperature inside the hydrogen gas lines to decrease.

    • To protect the hydrogen tank and related components, when the hydrogen gas temperature becomes -30 °C (-86 °F) or less, the discharging of compressed hydrogen gas must be stopped temporarily.

    • Monitor the Data List items "Smoothed Value of Hydrogen Tank 1 Temperature" and "Smoothed Value of Hydrogen Tank 2 Temperature" while performing compressed hydrogen gas discharging.

    • While performing compressed hydrogen gas discharging, periodically conduct leak checks of each connecting part of the SST (hydrogen venting tool).

    • If a leak is found, stop the discharging procedure.

    Tech Tips

    <Approximate Discharging Times for Compressed Hydrogen Gas>
    Hydrogen Gas Pressure Discharging Time (approximate)

    70 MPa (713.8 kgf/cm2, 10150 psi)

    		 180 minutes

    55 MPa (560.8 kgf/cm2, 7975 psi)

    		 150 minutes

    35 MPa (356.9 kgf/cm2, 5075 psi)

    		 110 minutes

    • The times listed above are only approximations, and times will vary depending on the actual work environment (ambient temperature, hydrogen tank gas temperature, etc,)

    • The (approximate) times listed above do not include time spent while the procedure is halted due to hydrogen gas temperature becoming too low.


    1. Lower the vehicle on the lift.

    2. B006JJ2C04
      *1 Auxiliary Battery
      *a Battery Charger

      Connect a charger to the auxiliary battery and put the auxiliary battery into a charging state.

    3. Using the GTS, enter the following menus: Body Electrical / Power Source Control / Utility / Auto Power OFF Cancel


      Body Electrical > Power Source Control > Utility
      Tester Display
      Auto Power OFF Cancel

    4. Using the GTS, enter the following menus: Powertrain / FC / Data List / Medium-range Hydrogen Pressure, High-range Hydrogen Pressure, Smoothed Value of Hydrogen Tank 1 Temperature, Smoothed Value of Hydrogen Tank 2 Temperature, Tank Side Hydrogen Detector Density


      Powertrain > FC > Data List
      Tester Display
      Medium-range Hydrogen Pressure
      High-range Hydrogen Pressure
      Smoothed Value of Hydrogen Tank 1 Temperature
      Smoothed Value of Hydrogen Tank 2 Temperature
      Tank Side Hydrogen Detector Density

      Tech Tips

      If the GTS unit setting is absolute pressure (abs), change it to gauge pressure (gauge).

    5. Open the tank shut valves of the No. 1 and No. 2 hydrogen tank assemblies.

      Note

      If the Data List item "Medium-range Hydrogen Pressure (gauge)" decreases to below 0.6 MPa (6.1 kgf/cm2, 87 psi) the tank shut valves of the No. 1 and No. 2 hydrogen tank assemblies will forcibly close.

    6. If the tank shut valves of the No. 1 and No. 2 hydrogen tank assemblies do not open, open the tank shut valves again.

    7. B006JM2C01
      *a SST (Venting Stand)

      Open the open/close valve of the SST (venting stand), and discharge compressed hydrogen gas.

      SST
      09404-62010   ( 09404-06010 )

    8. Read the Data List and check that "Smoothed Value of Hydrogen Tank 1 Temperature" and "Smoothed Value of Hydrogen Tank 2 Temperature" begin to decrease together.

      Tech Tips


      • By checking that the hydrogen tank temperatures are decreasing, it can be determined that the compressed hydrogen gas is discharging.

      • If either one of "Smoothed Value of Hydrogen Tank 1 Temperature" or "Smoothed Value of Hydrogen Tank 2 Temperature" does not decrease, perform the following procedure.


        1. Close the open/close valve of the SST (venting stand).

          Note

          To protect the tank shut valve, make sure to first close the open/close valve of the SST (venting stand).

        2. Close the tank shut valves of the No. 1 and No. 2 hydrogen tank assemblies.

        3. For the side where the hydrogen gas temperature does not decrease, check that the manual valve is open, and if it is closed, open the manual valve.

        4. Open the tank shut valves of the No. 1 and No. 2 hydrogen tank assemblies.

          Note

          If the Data List item "Medium-range Hydrogen Pressure (gauge)" decreases to below 0.6 MPa (6.1 kgf/cm2, 87 psi) the tank shut valves of the No. 1 and No. 2 hydrogen tank assemblies will forcibly close.

        5. If the tank shut valves of the No. 1 and No. 2 hydrogen tank assemblies do not open, open the tank shut valves again.

        6. Open the open/close valve of the SST (venting stand) again, and discharge the compressed hydrogen gas.

    9. Read the Data List, and if either of the items "Smoothed Value of Hydrogen Tank 1 Temperature" or "Smoothed Value of Hydrogen Tank 2 Temperature" have become -30 °C (-86 °F) or less:


      1. Close the open/close valve of the SST (venting stand) [*1]

        Note

        To protect the tank shut valve, make sure to first close the open/close valve of the SST (venting stand).

      2. Close the tank shut valves of the No. 1 and No. 2 hydrogen tank assemblies.[*2]

      3. Wait until both values "Smoothed Value of Hydrogen Tank 1 Temperature" and "Smoothed Value of Hydrogen Tank 2 Temperature" have increased to -20 °C (-68 °F) or more.[*3]

      4. Open the tank shut valves of the No. 1 and No. 2 hydrogen tank assemblies.[*4]

        Note

        If the Data List item "Medium-range Hydrogen Pressure (gauge)" decreases to below 0.6 MPa (6.1 kgf/cm2, 87 psi) the tank shut valves of the No. 1 and No. 2 hydrogen tank assemblies will forcibly close.

      5. If the tank shut valves of the No. 1 and No. 2 hydrogen tank assemblies do not open, open the tank shut valves again.[*5]

      6. Open the open/close valve of the SST (venting stand) and discharge compressed hydrogen gas again.[*6]

        Note

        During the compressed hydrogen gas discharging procedure, if it appears that either "Smoothed Value of Hydrogen Tank 1 Temperature" or "Smoothed Value of Hydrogen Tank 2 Temperature" are about to decrease to -30 °C (-86 °F) or less, repeat steps [*1] through [*6].

    10. Continue to monitor the Data List, and when the value of "Medium-range Hydrogen Pressure (gauge)" becomes 0.8 MPa (8.2 kgf/cm2, 116 psi), close the open/close valve of the SST (venting stand).

      Note


      • To protect the tank shut valve, make sure to first close the open/close valve of the SST (venting stand).

      • Forgetting to close the open/close valve of the SST (venting stand) and allowing the Data List item "Medium-range Hydrogen Pressure (gauge)" to decrease to below 0.6 MPa (6.1 kgf/cm2, 87 psi) will cause the tank shut valves of the No. 1 and No. 2 hydrogen tank assemblies to forcibly close.

    11. Check that the Data List item "Medium-range Hydrogen Pressure (gauge)" and the pressure on the pressure indicator of the SST (venting stand) are less than 0.8 MPa (8.2 kgf/cm2, 116 psi).

      Note


      • The pressure immediately after closing the open/close valve of the SST (venting stand) should be less than 0.8 MPa (8.2 kgf/cm2, 116 psi) for both the Data List item "Medium-range Hydrogen Pressure (gauge)" and on the pressure indicator of the SST (venting stand).

      • If either the Data List item "Medium-range Hydrogen Pressure (gauge)" or the pressure on the pressure indicator of the SST (venting stand) are 0.8 MPa (8.2 kgf/cm2, 116 psi) or greater, open the open/close valve of the SST (venting stand) and adjust the pressure.

      • After the pressure discharging, when the gas temperature inside the hydrogen tank increases, the pressure will also increase, so make sure to continue discharging until the pressure is less than 0.8 MPa (8.2 kgf/cm2, 116 psi).

      Tech Tips

      If the pressure immediately after closing the open/close valve of the SST (venting stand) is less than 0.8 MPa (8.2 kgf/cm2, 116 psi) for both the Data List item "Medium-range Hydrogen Pressure (gauge)" and on the pressure indicator of the SST (venting stand), then the pressurized hydrogen gas discharging procedure is complete.

    12. Close the tank shut valves of both the No. 1 and No. 2 hydrogen tank assemblies.

    13. Disconnect the SST (hydrogen venting tool).

      Click here

  10. DRAIN COMPRESSED HYDROGEN GAS (1 Tank Being Discharged)

    CAUTION:


    • B006JLX

      While discharging pressurized hydrogen gas, the temperature inside the tank decreases and frost may form on the outside. Do not touch tanks, piping, or SST (hydrogen venting tool) when frost has formed on them.

    • Touching tanks, piping, or SST (hydrogen venting tool) on which frost has formed could result in burn-like injuries due to frostbite.

    Note


    • Starting the discharging of compressed hydrogen gas will cause the temperature inside the hydrogen gas lines to decrease.

    • To protect the hydrogen tank and related components, when the hydrogen gas temperature becomes -30 °C (-86 °F) or less, the discharging of compressed hydrogen gas must be stopped temporarily.

    • When discharging compressed hydrogen gas from only a single hydrogen tank, the decrease of hydrogen gas temperature is more rapid than when discharging only one tank, so the discharging procedure will need to be stopped a greater number of times.

    • Because the temperature decrease in the hydrogen gas lines is more rapid, the following steps [*1] through [*6] must be repeated more often.

    • Monitor the Data List items "Smoothed Value of Hydrogen Tank 1 Temperature" and "Smoothed Value of Hydrogen Tank 2 Temperature" while performing compressed hydrogen gas discharging.

    • While performing compressed hydrogen gas discharging, periodically conduct leak checks of each connecting part of the SST (hydrogen venting tool).

    • If a leak is found, stop the discharging procedure.

    Tech Tips

    <Approximate Discharging Times for Compressed Hydrogen Gas>
    Hydrogen Gas Pressure Discharging Time (approximate)

    70 MPa (713.8 kgf/cm2, 10150 psi)

    		 90 minutes

    55 MPa (560.8 kgf/cm2, 7975 psi)

    		 75 minutes

    35 MPa (356.9 kgf/cm2, 5075 psi)

    		 55 minutes

    • The times listed above are only approximations, and times will vary depending on the actual work environment (ambient temperature, hydrogen tank gas temperature, etc,)

    • The (approximate) times listed above do not include time spent while the procedure is halted due to hydrogen gas temperature becoming too low.


    1. B006JFOC03
      *a Adjustment Bolt
      *b Manual Valve Open
      *c Manual Valve Closed
      *d Clockwise

      If the tank shut valve of the No. 1 hydrogen tank assembly can not be opened:


      1. Using an 8 mm socket hexagon wrench, rotate the adjustment bolt in the clockwise direction to close the manual valve of the No. 1 hydrogen tank assembly.

        Torque:
        20 N*m  { 204 kgf*cm, 15 ft.*lbf }

        Note


        • The manual valve shuts off the pressure from the hydrogen tank assembly, so be careful not to damage the hexagonal portion.

        • If the hexagonal portion has been damaged, the No. 1 hydrogen tank assembly must be replaced.

    2. B006JHUC03
      *a Adjustment Bolt
      *b Manual Valve Open
      *c Manual Valve Closed
      *d Clockwise

      If the tank shut valve of the No. 2 hydrogen tank assembly can not be opened:


      1. Using an 8 mm socket hexagon wrench, rotate the adjustment bolt in the clockwise direction to close the manual valve of the No. 2 hydrogen tank assembly.

        Torque:
        20 N*m  { 204 kgf*cm, 15 ft.*lbf }

        Note


        • The manual valve shuts off the pressure from the hydrogen tank assembly, so be careful not to damage the hexagonal portion.

        • If the hexagonal portion has been damaged, the No. 2 hydrogen tank assembly must be replaced.

    3. Lower the vehicle on the lift.

    4. B006JJ2C04
      *1 Auxiliary Battery
      *a Battery Charger

      Connect a charger to the auxiliary battery and put the auxiliary battery into a charging state.

    5. Using the GTS, enter the following menus: Body Electrical / Power Source Control / Utility / Auto Power OFF Cancel


      Body Electrical > Power Source Control > Utility
      Tester Display
      Auto Power OFF Cancel

    6. Using the GTS, enter the following menus: Powertrain / FC / Data List / Medium-range Hydrogen Pressure, High-range Hydrogen Pressure, Smoothed Value of Hydrogen Tank 1 Temperature, Smoothed Value of Hydrogen Tank 2 Temperature, Tank Side Hydrogen Detector Density


      Powertrain > FC > Data List
      Tester Display
      Medium-range Hydrogen Pressure
      High-range Hydrogen Pressure
      Smoothed Value of Hydrogen Tank 1 Temperature
      Smoothed Value of Hydrogen Tank 2 Temperature
      Tank Side Hydrogen Detector Density

      Tech Tips

      If the GTS unit setting is absolute pressure (abs), change it to gauge pressure (gauge).

    7. Open the tank shut valves of the No. 1 and No. 2 hydrogen tank assemblies.

      Note

      If the Data List item "Medium-range Hydrogen Pressure (gauge)" decreases to below 0.6 MPa (6.1 kgf/cm2, 87 psi) the tank shut valves of the No. 1 and No. 2 hydrogen tank assemblies will forcibly close.

    8. If the tank shut valves of the No. 1 and No. 2 hydrogen tank assemblies do not open, open the tank shut valves again.

    9. B006JM2C01
      *a SST (Venting Stand)

      Open the open/close valve of the SST (venting stand), and discharge compressed hydrogen gas.

      SST
      09404-62010   ( 09404-06010 )

    10. Read the Data List, and if either of the items "Smoothed Value of Hydrogen Tank 1 Temperature" or "Smoothed Value of Hydrogen Tank 2 Temperature" have become -30 °C (-86 °F) or less:


      1. Close the open/close valve of the SST (venting stand) [*1]

        Note

        To protect the tank shut valve, make sure to first close the open/close valve of the SST (venting stand).

      2. Close the tank shut valves of the No. 1 and No. 2 hydrogen tank assemblies.[*2]

      3. Wait until both values "Smoothed Value of Hydrogen Tank 1 Temperature" and "Smoothed Value of Hydrogen Tank 2 Temperature" have increased to -20 °C (-68 °F) or more.[*3]

      4. Open the tank shut valves of the No. 1 and No. 2 hydrogen tank assemblies.[*4]

        Note

        If the Data List item "Medium-range Hydrogen Pressure (gauge)" decreases to below 0.6 MPa (6.1 kgf/cm2, 87 psi) the tank shut valves of the No. 1 and No. 2 hydrogen tank assemblies will forcibly close.

      5. If the tank shut valves of the No. 1 and No. 2 hydrogen tank assemblies do not open, open the tank shut valves again.[*5]

      6. Open the open/close valve of the SST (venting stand) and discharge compressed hydrogen gas again.[*6]

        Note

        During the compressed hydrogen gas discharging procedure, if it appears that either "Smoothed Value of Hydrogen Tank 1 Temperature" or "Smoothed Value of Hydrogen Tank 2 Temperature" are about to decrease to -30 °C (-86 °F) or less, repeat steps [*1] through [*6].

    11. Continue to monitor the Data List, and when the value of "Medium-range Hydrogen Pressure (gauge)" becomes 0.8 MPa (8.2 kgf/cm2, 116 psi), close the open/close valve of the SST (venting stand).

      Note


      • To protect the tank shut valve, make sure to first close the open/close valve of the SST (venting stand).

      • Forgetting to close the open/close valve of the SST (venting stand) and allowing the Data List item "Medium-range Hydrogen Pressure (gauge)" to decrease to below 0.6 MPa (6.1 kgf/cm2, 87 psi) will cause the tank shut valves of the No. 1 and No. 2 hydrogen tank assemblies to forcibly close.

    12. Check that the Data List item "Medium-range Hydrogen Pressure (gauge)" and the pressure on the pressure indicator of the SST (venting stand) are less than 0.8 MPa (8.2 kgf/cm2, 116 psi).

      Note


      • The pressure immediately after closing the open/close valve of the SST (venting stand) should be less than 0.8 MPa (8.2 kgf/cm2, 116 psi) for both the Data List item "Medium-range Hydrogen Pressure (gauge)" and on the pressure indicator of the SST (venting stand).

      • If either the Data List item "Medium-range Hydrogen Pressure (gauge)" or the pressure on the pressure indicator of the SST (venting stand) are 0.8 MPa (8.2 kgf/cm2, 116 psi) or greater, open the open/close valve of the SST (venting stand) and adjust the pressure.

      • After the pressure discharging, when the gas temperature inside the hydrogen tank increases, the pressure will also increase, so make sure to continue discharging until the pressure is less than 0.8 MPa (8.2 kgf/cm2, 116 psi).

      Tech Tips

      If the pressure immediately after closing the open/close valve of the SST (venting stand) is less than 0.8 MPa (8.2 kgf/cm2, 116 psi) for both the Data List item "Medium-range Hydrogen Pressure (gauge)" and on the pressure indicator of the SST (venting stand), then the pressurized hydrogen gas discharging procedure is complete.

    13. Close the tank shut valves of both the No. 1 and No. 2 hydrogen tank assemblies.

    14. Disconnect the SST (hydrogen venting tool).

      Click here

  11. DISCONNECT SST (HYDROGEN VENTING TOOL)

    CAUTION:


    • B006JLX

      While discharging pressurized hydrogen gas, the temperature inside the tank decreases and frost may form on the outside. Do not touch tanks, piping, or SST (hydrogen venting tool) when frost has formed on them.

    • Touching tanks, piping, or SST (hydrogen venting tool) on which frost has formed could result in burn-like injuries due to frostbite.


    1. B006JFOC03
      *a Adjustment Bolt
      *b Manual Valve Open
      *c Manual Valve Closed
      *d Clockwise

      Using an 8 mm socket hexagon wrench, rotate the adjustment bolt in the clockwise direction to close the manual valve of the No. 1 hydrogen tank assembly.

      Torque:
      20 N*m  { 204 kgf*cm, 15 ft.*lbf }

      Note


      • The manual valve shuts off the pressure from the hydrogen tank assembly, so be careful not to damage the hexagonal portion.

      • If the hexagonal portion has been damaged, the No. 1 hydrogen tank assembly must be replaced.

      Tech Tips

      If the manual valve is closed at the time of discharging compressed hydrogen gas, this procedure is unnecessary.

    2. B006JHUC03
      *a Adjustment Bolt
      *b Manual Valve Open
      *c Manual Valve Closed
      *d Clockwise

      Using an 8 mm socket hexagon wrench, rotate the adjustment bolt in the clockwise direction to close the manual valve of the No. 2 hydrogen tank assembly.

      Torque:
      20 N*m  { 204 kgf*cm, 15 ft.*lbf }

      Note


      • The manual valve shuts off the pressure from the hydrogen tank assembly, so be careful not to damage the hexagonal portion.

      • If the hexagonal portion has been damaged, the No. 2 hydrogen tank assembly must be replaced.

      Tech Tips

      If the manual valve is closed at the time of discharging compressed hydrogen gas, this procedure is unnecessary.

    3. B006JM2C01
      *a SST (Venting Stand)

      Open the open/close valve of the SST (venting stand) and discharge the compressed hydrogen gas remaining inside the SST (flexible hose).

      SST
      09404-62010   ( 09404-06010 )

      Note


      • Do not disconnect the SST (flexible hose) while there is still pressure remaining inside it.

      • Continue discharging until the pressure gauge of the SST (Venting Stand) becomes "0".

    4. Before performing the disconnection procedure, if there are any contaminants such as water droplets adhering near the medium pressure leak check port of the hydrogen supply regulator assembly, wipe them away before performing the procedure.

    5. B006JIAC01
      *a SST (Flexible Hose)
      *b SST (Venting Stand)

      Disconnect the SST (flexible hose) from the SST (Venting Stand).

      SST
      09404-62010   ( 09404-06010, 09404-06020 )
    6. B006JKOC01
      *1 Hydrogen Supply Regulator Union
      *a Body
      *b Paint Mark

      Apply paint marks to the hydrogen supply regulator union and the body of the hydrogen supply regulator assembly as shown in the illustration.

      Tech Tips

      When loosening the SST (flexible hose), there is a possibility that the hydrogen supply regulator union could turn together with it and be loosened, so applying paint marks will enable judgment of whether the hydrogen supply regulator union has been loosened.

    7. B006JEJC01
      *a SST (Flexible Hose)
      *b SST (Open End Wrench)

      Using SST (open end wrench), remove the SST (flexible hose) from the hydrogen supply regulator union.

      SST
      09922-10240
      09404-62010   ( 09404-06020 )
    8. B006JK5

      Remove the O-ring from the hydrogen supply regulator union.

    9. B006JHEC01
      *a Protective Tape

      To prevent damage to the seal portions and threaded portions, and to prevent foreign matter such as dust or metal fragments from entering the openings, cover the seal portions, threaded portions, and openings of the hydrogen supply regulator union with protective tape.

    10. B006JG3C01
      *a Correct
      *b Incorrect
      *c Paint Mark

      Check that the hydrogen supply regulator union has not been loosened.

      Tech Tips

      If the hydrogen supply regulator union has been loosened, there is the possibility of a compressed hydrogen gas leak, so it is necessary to remove the hydrogen supply regulator union and replace the O-ring with a new one.

    11. Procedures for when the hydrogen supply regulator union has been loosened:


      1. B006JLS

        Remove the hydrogen supply regulator union.

        Note

        When frost has formed on the hydrogen tank assembly or piping, water droplets may be formed when the frost begins to melt. If water droplets enter the tank or piping, it could result in blockage of the hydrogen piping, so do not allow water droplets to enter the tank or piping.

      2. B006JG8C01
        *a Protective Tape

        To prevent foreign matter such as dust or metal fragments from entering the openings, cover the seal portions, threaded portions, and openings of the hydrogen supply regulator union installation portion with protective tape.

      3. B006JK2

        Remove the O-ring from the hydrogen supply regulator union.

        Note

        Perform the procedure by hand. Do not use any tools.

      4. Clean and degrease the threaded portion of the hydrogen supply regulator union.

      5. B006JIHC01
        *1 Hydrogen Supply Regulator Union
        *a Protective Tape

        To prevent the O-ring from being damaged during installation, apply protective tape as shown in the illustration.

        Tech Tips

        Cover the hydrogen supply regulator union with protective tape so that the threaded portion and the hole cannot be seen.

      6. Coat a new O-ring with TOYOTA Genuine FC Grease.

      7. B006JG4

        Install the O-ring to the hydrogen supply regulator union.

        Note


        • Make sure not to damage the O-ring.

        • Make sure the O-ring is not twisted.

      8. Remove the protective tape from the hydrogen supply regulator union.

        Note

        When frost has formed on the hydrogen tank assembly or piping, water droplets may be formed when the frost begins to melt. If water droplets enter the tank or piping, it could result in blockage of the hydrogen piping, so do not allow water droplets to enter the tank or piping.

      9. B006JJ0

        Coat the O-ring and the threaded portion of the hydrogen supply regulator union with TOYOTA Genuine FC Grease.

      10. To prevent the hydrogen supply regulator union installation portion from being contaminated by dust, metal fragments, etc., do not remove the protective tape from it until immediately before performing the work.

        Note

        When frost has formed on the hydrogen tank assembly or piping, water droplets may be formed when the frost begins to melt. If water droplets enter the tank or piping, it could result in blockage of the hydrogen piping, so do not allow water droplets to enter the tank or piping.

      11. Install the hydrogen supply regulator union.

        Torque:
        41.5 N*m  { 423 kgf*cm, 31 ft.*lbf }

        Note

        When installing the O-ring, make sure that it is not pinched.

    12. To prevent damage to the seal portions and threaded portions, and to prevent foreign matter such as dust or metal fragments from entering the openings, do not remove the protective tape covering the seal portions, threaded portions, and openings of the hydrogen supply regulator union until immediately before performing work.

      Note

      When frost has formed on the hydrogen tank assembly or piping, water droplets may be formed when the frost begins to melt. If water droplets enter the tank or piping, it could result in blockage of the hydrogen piping, so do not allow water droplets to enter the tank or piping.

    13. B006JFS

      Apply TOYOTA Genuine FC Grease to a new O-ring and to the threaded portion of the hydrogen supply regulator union.

    14. Install the O-ring to the hydrogen supply regulator union.

      Note

      During installation, make sure not to damage the O-ring.

    15. B006JHN

      Install the No. 1 hydrogen supply regulator plug to the hydrogen supply regulator union.

      Torque:
      25 N*m  { 255 kgf*cm, 18 ft.*lbf }
    16. B006JDNC04
      *a Adjustment Bolt
      *b Manual Valve Closed
      *c Manual Valve Open
      *d Counterclockwise

      Using an 8 mm socket hexagon wrench, rotate the adjustment bolt counterclockwise, and open the No. 1 hydrogen tank assembly manual valve.

      Note


      • The manual valve shuts off the pressure from the hydrogen tank assembly, so be careful not to damage the hexagonal portion.

      • If the hexagonal portion is damaged, it will be impossible to operate the adjustment bolt.

      • Do not rotate the adjustment bolt more than 4 rotations.

      • Rotating the adjustment bolt more than 4 rotations could damage the manual valve.

      • If the manual valve is damaged, it will be necessary to replace the No. 1 hydrogen tank assembly.

    17. B006JMMC04
      *a Adjustment Bolt
      *b Manual Valve Closed
      *c Manual Valve Open
      *d Counterclockwise

      Using an 8 mm socket hexagon wrench, rotate the adjustment bolt counterclockwise, and open the No. 2 hydrogen tank assembly manual valve.

      Note


      • The manual valve shuts off the pressure from the hydrogen tank assembly, so be careful not to damage the hexagonal portion.

      • If the hexagonal portion is damaged, it will be impossible to operate the adjustment bolt.

      • Do not rotate the adjustment bolt more than 4 rotations.

      • Rotating the adjustment bolt more than 4 rotations could damage the manual valve.

      • If the manual valve is damaged, it will be necessary to replace the No. 2 hydrogen tank assembly.

    18. Connect the FC exhaust pipe with the 3 bolts.

      Torque:
      5.0 N*m  { 51 kgf*cm, 44 in.*lbf }

  12. INSTALL NO. 1 FLOOR UNDER COVER

    Click here

  13. INSTALL NO. 2 FLOOR UNDER COVER

    Click here

  14. INSTALL FRONT FLOOR CENTER COVER RH

    Click here

  15. INSTALL FRONT FLOOR CENTER COVER LH

    Click here