SMB-169 – Venting Tank (Solenoid Valve Stuck Closed or Not Operating) Installation of CNG High Pressure Solenoid Valve on Tank – New Flyer Xcelsior

SEOCONTENT-START
SMB-169 1 of 4
SERVICE MANUAL BULLETIN
This Service Manual Bulletin is prepared by the Publications Department of New Flyer Industries
Canada ULC. Refer to details below.
The New Flyer vehicles described in this manual may be protected by one or more
patents and design applications or registrations in the United States and Canada,
and in other countries. Refer to “Vehicle Patent Information” in this manual.
Copyright © 2017 New Flyer Industries Canada ULC
ISSUE DATE: May 17 2017
SMB-169
APPLICABILITY
VEHICLE LENGTH  30ft.  35ft.  40ft.  60ft.  ALL
VEHICLE TYPE
 Xcelsior®  MiDi®  Invero®
 ALL
 Low Floor  High Floor
FUEL TYPE
 Diesel  Diesel/Electric  CNG  LNG
 ALL
 Fuel Cell  Trolley/Electric  Battery/Electric
SUBJECT Venting Tank (Solenoid Valve Stuck Closed or Not Operating)
Installation of CNG High Pressure Solenoid Valve on Tank
SECTION TITLE 7 – FUEL SYSTEM
DETAILS This bulletin provides a procedure for venting the tanks when the solenoid
valve is stuck closed or not operating, and a procedure for the
installation of the solenoid valve on the CNG tank of your New Flyer Vehicle.
This bulletin supersedes all prior information on this subject already provided
in your New Flyer Service Manuals. Make this Service Bulletin
available to service personnel to inform them of changed information.
2 of 4 SMB-169
SERVICE MANUAL BULLETIN
SMB-169
The New Flyer vehicles described in this manual may be protected by one or more
patents and design applications or registrations in the United States and Canada,
and in other countries. Refer to “Vehicle Patent Information” in this manual.
Copyright © 2017 New Flyer Industries Canada ULC
1. PURPOSE
Some New Flyer Service Manuals may not
contain the following procedures:
❒ venting a CNG tank if the solenoid valve is
stuck closed or not operating;
❒ installation of the solenoid valve on the
tank.
These procedures were not available at
the time of publication and are provided in
this bulletin.
1.1. Venting Tank (Solenoid Valve
Stuck Closed or Not Operating)
1. Set the Battery Disconnect switch to the
OFF position.
2. Close the fuel tank manual shut-off valve
and discharge the gas from Zone 1 and
Zone 2.
☞NOTE:
The manual shut-off must be closed for the
valve with the damaged coil, as well as all
neighboring valves involved in the system,
even if they are functioning properly.
3. Unscrew the valve’s coil nut.
4. Remove the coil nut being careful not to
drop the internal O-ring.
5. Remove the coil being careful not to drop
the protection gasket.
6. Exchange the faulty coil with a good one
from the neighboring valve or the maintenance
tooling. After installing the coil onto
the faulty valve, proceed to step 9 to defuel
the fuel tank.
7. If exchanging the coil does not work to fix
the solenoid, the internal components of
the solenoid are defective. The internal
solenoid components can be bypassed by
proceeding as follows:
a. Ensure that the manual shut-off is fully
closed.
Some residual gas may be trapped
inside the solenoid valve.
b. Carefully unscrew the solenoid sleeve
using a 25 mm wrench
c. Disassemble the solenoid sleeve.
d. Take out the solenoid internal parts.
See “Fig. 1: Take out the solenoid internal
parts” on page 2.
e. Reassemble the solenoid sleeve.
Torque to 14.8 ft-lb. ± 1 ft-lb. (20 ± 1
Nm) without the internal parts.
Fig. 1: Take out the solenoid internal parts
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SMB-169 3 of 4
SERVICE MANUAL BULLETIN
SMB-169
The New Flyer vehicles described in this manual may be protected by one or more
patents and design applications or registrations in the United States and Canada,
and in other countries. Refer to “Vehicle Patent Information” in this manual.
Copyright © 2017 New Flyer Industries Canada ULC
8. It is now possible to discharge the gas
from the fuel tank by carefully opening the
manual shut-off valve.
All tank solenoid valves must be
CLOSED during this procedure and
remain CLOSED.
9. Ensure the main (emergency) shut-off
valve is open.
10.Connect a line from the recovery system to
the purge line shut-off valve.
11.Record the actual system pressure.
12.Slowly rotate the purge line shut-off valve
to the fully open (vertical) position.
13.Allow the gas in Zone Two to completely
depressurize as indicated by a “zero” reading
on the pressure gauge and no further
flow through the vent line.
14.Rotate the purge line shut-off valve to the
closed (horizontal) position.
15.Open the solenoid valve manual shut-off
on the tank to be vented by rotating the
valve knob.
DO NOT fully open the purge line shutoff
valve in the following step.
16.Slowly rotate the purge line shut-off valve
to the fully open (vertical) position.
17.Allow the gas in Zone Three to completely
depressurize as indicated by a “zero” reading
on the pressure gauge and no further
flow through the vent line.
18.Rotate the purge line shut-off valve to the
closed (horizontal) position.
19.Remove the tank solenoid valve, if
required, and perform the necessary maintenance
of Zone Three components. Refer
to 1.2. “Installation of CNG High Pressure
Solenoid Valve on Tank” on page 4 in this
bulletin for procedure.
20.Refer to Section 7 in your New Flyer Service
Manual pressure equalizing procedure
if the tank will not be repressurized
immediately.
4 of 4 SMB-169
SERVICE MANUAL BULLETIN
SMB-169
The New Flyer vehicles described in this manual may be protected by one or more
patents and design applications or registrations in the United States and Canada,
and in other countries. Refer to “Vehicle Patent Information” in this manual.
Copyright © 2017 New Flyer Industries Canada ULC
1.2. Installation of CNG High Pressure
Solenoid Valve on Tank
For proper installation the valve must be
correctly installed by properly trained maintenance
personnel.
Installation tools required include a torque
wrench, ESA special mounting tools and
Parker Super O-Lube or suitable substitute
for the O-ring. Proceed as follows:
1. Apply silicone grease lubricant to the
O-ring sparingly.
2. Carefully engage the valve body threads to
the CNG tank 1 1/8″ – 12 UNF port fitting.
3. Manually thread the valve onto the tank.
4. Torque the valve to 83 ± 13 ft-lb.
5. Apply a light coating of silicone grease on
the O-rings and install the male adapter
and plug into the 9/16″ – 18 threaded ports
of the solenoid valve. Torque the fittings 20
to 30 ft-lb. (27 to 47 Nm).
6. Rotate the tank as required to align plumbing
ports.
☞NOTE:
Refer to Section 7 in your New Flyer Service
Manual for tank installation procedure.
7. Install PRD vent and fill/engine feed lines
onto the standard connectors and tighten
Swagelok® fitting. Refer to Section 7 of
your New Flyer Service Manual for Swagelock
fitting installation instructions.
8. Attach the electrical leads.
9. Fill the fuel tanks from the storage facility.
10.Check the solenoid valve for leaks using
combustible gas detector such as the
Snap-On ACT 8800®. This particular unit
can detect localized gas leaks from 50 to
1000 PM.
☞NOTE:
Liquid solutions such as SNOOP® can
also be used. DO NOT use make-shift
soapy water solutions.
11.Make sure the quarter-turn shut-off valve is
in the ON position. The handle is in the on
position when it is aligned (parallel) with
the fuel line.
☞NOTE:
Make sure the fill box door is firmly closed
before attempting to start the engine. The
fill box contains a proximity sensor to prevent
the engine from starting when the
door is open. The engine ignition is disabled
and the high-pressure solenoid
valves are shut off to prevent fuel flow to
the gas mixer when the proximity sensor is
open.
12.Turn the Master Run switch to DAY or
NIGHT operating position. Turn the ignition
on to activate the starter. As the starter
spins the engine up to 400 RPM, the solenoid
valves will energize and allow fuel to
flow through the filtering and regulating
system to the fuel mixer, starting the
engine.
☞NOTE:
If the engine does not start, make sure the
fill box is firmly closed and that the solenoid
valve wires are connected.
13.Run the engine up for a minute or so to
allow the fuel delivery system to stabilize,
then shut the engine down.
DO NOT perform any corrective action
or other maintenance on a pressurized
system. Perform component servicing
or maintenance only after the affected
zone has been isolated and depressurized.
Refer to 1.1. “Venting Tank (Solenoid
Valve Stuck Closed or Not Operating)” on
page 2 in this bulletin for depressurizing
procedure.
14.Recheck the solenoid valve and the run/fill
loop connections with the Snap-On ACT
8800® combustible gas detector. Tighten
any fittings as required. Use a backup
wrench to prevent overtightening.
15.Open the fill box door and check the high
and low pressure gauges for pressure
readings. The high pressure gauge should
show 200 to 3,600 psi (1,375 to 24,800
kPa), the low pressure gauge should show
94 to 120 psi (648 to 827 kPa).