A Workshop’s Guide to Servicing Fuel

Hydrogen fuel cell vehicles (FCEVs) are unique in how they generate power and require special attention in servicing. This blog will take you through everything you need to know, step-by-step, about how these vehicles work and how workshops should handle them.
What is a Hydrogen Fuel Cell Vehicle?

Hydrogen-Powered: These vehicles use hydrogen gas stored in pressurized tanks.
Zero Emissions: The only byproduct is water vapor, making them environmentally friendly.
Fuel Cell Stack: This is the heart of the vehicle, where hydrogen and oxygen react to generate electricity.
Electric Motor: Like electric vehicles (EVs), hydrogen cars use an electric motor powered by the fuel cell stack​.

How Does a Hydrogen Fuel Cell Work?

Hydrogen in, Electricity Out: Hydrogen from the tank enters the fuel cell stack, passing through an anode with a platinum catalyst.
Protons and Electrons: The catalyst splits hydrogen into protons and electrons. Protons pass through a membrane, while electrons create an electric current.
Oxygen Reaction: Oxygen from the air combines with the hydrogen, producing electricity and water.

What Should a Workshop Know?
1. Fuel Cell Stack Maintenance

Importance: The fuel cell stack is vital for generating power. It must be inspected regularly for wear and potential leaks.
What to Do: Check for contamination or damage and ensure the platinum catalyst is working effectively​.

2. Hydrogen Storage Tank

High Pressure: The hydrogen is stored at around 10,000 psi, meaning the tanks must be robust and safe.
What to Do: Inspect tanks for structural integrity and check for leaks or signs of wear. Maintaining pressure and temperature is crucial​.

3. Dealing with Hydrogen Leaks

Critical Safety Issue: Hydrogen is flammable, so leaks are dangerous.
What to Do: Workshops need specialized detection tools for leaks and technicians should be trained to handle them safely​.

4. Cooling System

Why Important: The chemical reaction inside the fuel cell generates heat, requiring a cooling system to prevent damage.
What to Do: Regularly check the coolant levels, hoses, and heat exchangers to avoid overheating.

5. Battery and Electric Components

Electric Motor: Like EVs, FCEVs have electric components that power the motor.
What to Do: Inspect the high-voltage battery and other electrical systems to ensure they are functioning properly.

6. Proper Hydrogen Fueling Procedures

Fueling Process: Refueling a hydrogen car is similar to gas refueling but requires strict procedures due to the high pressure.
What to Do: Train technicians and educate customers on the proper fueling technique to avoid mishaps​.

7. Cold Weather Challenges

Temperature Sensitivity: Cold temperatures can reduce the efficiency of hydrogen fuel cells.
What to Do: Insulate key components and ensure the fuel cell stack is within the optimal temperature range during winter.

Key Differences Between Hydrogen Cars and Electric Vehicles (EVs)

Refueling Time: Hydrogen cars can be refueled in minutes, unlike EVs, which take hours to charge.
Range: FCEVs typically offer a longer range compared to most battery-electric vehicles.
Emissions: Both EVs and FCEVs are zero-emission, but hydrogen cars only emit water vapor.

Challenges in Servicing Hydrogen Cars

High Cost of Infrastructure: Building a hydrogen refueling station costs around $1 million, which makes these cars less common.
Complexity of Parts: The use of precious metals like platinum in the fuel cell stack increases the cost of parts and repairs​.
Lack of Technicians: Not all workshops are equipped or trained to handle FCEVs, making servicing more difficult.

What to Expect in the Future

Growing Popularity: While hydrogen cars are still niche, companies like BMW and Toyota are investing heavily in hydrogen technology.
Better Infrastructure: As the number of hydrogen stations increases, servicing these cars will become more common​.

Conclusion: Workshops Must Adapt
Hydrogen fuel cell vehicles offer exciting potential, but they also require specialized maintenance. Workshops need to invest in proper equipment and training to safely and effectively service these vehicles.
As hydrogen infrastructure expands, staying informed and prepared will be key to ensuring that workshops can handle the unique demands of hydrogen-powered cars.