WORK INSTRUCTIONS
SUBJECT

Hydrogen Tank OTV Setscrew Replacement
APPLICABLE MODELS / VINS
Model: Tre FCEV

OVERVIEW
Under certain conditions, trapped hydrogen (H2) gas can cause the on-tank valve (OTV) to close unintentionally, resulting
in a fault that could lead to a loss of propulsion. Replacing the original set screw with a modified set screw can solve the
issue in most cases.

PARTS REQUIRED
Qty.

Part No.

Description

As required

SN00000409

Modified setscrew, OTV

COMMENTS
MATERIALS REQUIRED
Qty.

Part No.

Description

1

Commercially available

#1 Robertson drive bit

1

Commercially available

#2 Robertson drive bit

COMMENTS
LABOR INFORMATION
Labor Operation: Hydrogen Tank OTV Setscrew Replacement
Labor Codes:

13-000000001; Setscrew replacement
07-762010103; LV battery box assembly removal (If performing work on tank #2)

Labor Times:

0.8 hours (for labor code 13-000000001)
1.4 hours (for labor code 07-762010103)

COMMENTS
If performing work on tank #2, add both labor times.
DISPOSITION INFORMATION
N/A

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WORK INSTRUCTIONS
PROCEDURE

Preliminary Steps
1.

Place the vehicle into Accessory or Permanent Accessory.

2. On the infotainment screen, find the “Safe Shutdown” section under Settings > SYSTEM.
Note: The Safe Shutdown section appears at the top of the SYSTEM page and will only appear when the
vehicle is in Accessory or Permanent Accessory.
3. Tap ON to select safe shutdown as shown in Figure 1.

Figure 1, Safe Shutdown (1 of 3)

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Preliminary Steps Cont.
4. Press the START/STOP button to shut down the vehicle.
5. While the vehicle’s system is shutting down, the infotainment screen shows a notification that shutdown is in
progress as shown in Figure 2.

Figure 2, Safe Shutdown (2 of 3)
6. When the safe shutdown is complete, the infotainment screen will briefly show a confirmation that the MBD can
be turned off as shown in Figure 3.

Figure 3, Safe Shutdown (3 of 3)

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WORK INSTRUCTIONS
PROCEDURE

Preliminary Steps Cont.
Risk of damage. Before tilting the radiator and cab, the upper center front bumper trim must be removed.
Failure to follow these instructions may cause vehicle damage.
7. Lift the front grille (1) shown in Figure 4.
8. Locate and twist the two bumper trim (2) clips to the unlock position.
9. Remove the bumper trim (2) from the vehicle and place in a safe place.

Figure 4, Bumper Trim Removal

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WORK INSTRUCTIONS
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Preliminary Steps Cont.
Risk of damage. Before tilting the cab, the radiator must be tilted until the cab strap is fully engaged. Failure to
follow these instructions may cause vehicle damage.
10. Locate the radiator release paddle (3A) or T-handle (3B) on the passenger side of the vehicle shown in Figure 5.
Note: Radiator release type will depend on what is installed on the vehicle.
11. While holding the radiator (4) pull the T-handle (3).

Figure 5, Radiator Release

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WORK INSTRUCTIONS
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Preliminary Steps Cont.
12. Tilt the radiator (4) down until the cab strap (5) is fully engaged shown in Figure 6.

Figure 6, Radiator Tilt

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Preliminary Steps Cont.
13. Tilt the cab until it is in most forward position.
14. Turn the manual battery disconnect (MBD) to the OFF position to disconnect the vehicle’s electrical system as
shown in Figure 7.

Figure 7, MBD Off

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WORK INSTRUCTIONS
PROCEDURE

OTV and Setscrew Location
Hydrogen is extremely flammable and explosive when mixed with air, can displace oxygen causing
asphyxiation, and may ignite from sparks or open flames. Do this procedure in a well-ventilated area.
Failure to follow these instructions may result in death or serious injury.
Personnel shall wear personal protective equipment including safety goggles when replacing the setscrew.
Failure to follow these instructions may result in minor or moderate injury.
Note: Before starting this procedure, make sure the correct stuck tank(s) have been identified. Contact the Nikola Pulse
Uptime Center for further guidance.
Note: Only Nikola trained personnel are authorized to perform the setscrew replacement.
1.

Locate the faulted OTV(s) where the setscrew is to be replaced. See Figure 8 for tank locations.

2. Identify the correct setscrew (1) to be replaced as shown in Figure 8.
Note: Make sure the correct setscrew has been identified for removal.

Figure 8, OTV / Setscrew Location
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WORK INSTRUCTIONS
PROCEDURE

Old OTV Setscrew Removal
The set screw is made from soft plastic and glued in place. Using a 2.5 mm hex will round out the setscrew. Care
must be taken so as not to damage the threads or to the setscrew so much that it releases particles into the
valve body which may cause a tank replacement.
1.

Use a #1 Robertson drive bit to carefully remove the old setscrew (1) from the OTV (2), pressing the tool in hard
while turning it counterclockwise slowly and smoothly so as not to damage the setscrew (1) by rounding it out.
Note: If the #1 Robertson drive bit rounds out the setscrew, use a #2 Robertson drive bit and repeat
Steps 2 and 3. If the #2 Robertson drive bit is unable to remove the setscrew, the tank may need to be
replaced. Contact the Nikola Pulse Uptime Center for further guidance.

Figure 9, Old OTV Setscrew Removal
Make sure no water or foreign debris enters the setscrew bore when replacing the setscrew. Incorrect
operation and/or damage to the OTV may occur.
2. Inspect the setscrew hole for any foreign debris and clean as needed.

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WORK INSTRUCTIONS
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New OTV Setscrew Installation
Personnel shall wear personal protective equipment including safety goggles when replacing the setscrew.
Failure to follow these instructions may result in minor or moderate injury.
Note: Only Nikola trained personnel are authorized to perform the setscrew replacement.
1.

Before installation, make sure the setscrew hole is free of foreign debris.
Make sure not to cross thread the new setscrew when installed. Damage to the setscrew and OTV may occur.

2. Use a 2.5 mm hex bit to carefully install the new setscrew (1), with the slotted side of the setscrew (1) first, into the
setscrew hole in the OTV (2) until it bottoms out as seen in Figure 10.
Make sure not to over torque the setscrew. Damage to the setscrew and OTV may occur.
3. Tighten the setscrew (1) until a sharp rise in torque is felt.

Figure 10, New OTV Setscrew Installation

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WORK INSTRUCTIONS
PROCEDURE

Record OTV Information
1.

Record the following information:
a. Date of the screw removal.
b. Running number (1) (four digit numeric) from the affected OTV label as seen in Figure 11.
c. Production date (2) (YY-MM-DD) from the affected OTV label as seen in Figure 11.
d. Serial number from the affected H2 tank.
e. VIN of the vehicle

Figure 11, OTV Label
2. Send the recorded information to the Nikola Pulse Uptime Center.

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WORK INSTRUCTIONS
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Final Steps
1.

Turn the MBD to the ON position to reconnect the vehicle’s electrical system as shown in Figure 12.

Figure 12, MBD On
2. Tilt the cab back to its original position.

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Final Steps Cont.
3. Push the radiator (1) back until it locks into place shown in Figure 13.

Figure 13, Radiator Tilt and Lock

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Final Steps Cont.
4. Reinstall the bumper trim (2) onto the vehicle shown in Figure 14.
5. Locate and twist the two bumper trim (2) clips to the lock position.
6. Lower the front grille (1) on the vehicle.

Figure 14, Bumper Trim Install

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