VSR-WI-005-A-Inspection Procedure – McNeilus

SAFETY NOTICE

VSR-WI-005-A-Inspection Procedure

NHTSA Campaign Number: 19V-656

 

Vehicle Safety Recall – Technical Service Bulletin

 

Inspection Procedure

PROMPT ACTION REQUIRED

Attention:	McNeilus Service Technicians
Subject:	Pressure Relief Device (PRD) on CNG Tank
Models Affected:	McNeilus Concrete Standard and Bridgemaster V Mixers fitted with Emcara PRD valves on the CNG tanks
Date Revised:	November 2019

 

Purpose:

McNeilus Truck and Manufacturing, Inc. has been alerted by our supplier that a concern affecting safety exists in some Emcara Pressure Relief Device (PRD) valves on CNG tanks (for your information, Emcara’s NHTSA Recall number is 15E059). Some McNeilus Standard and Bridgemaster V Concrete Mixer models were shipped with an Emcara CNG PRD which may not vent properly. The purpose of the thermal PRD is to relieve pressure in the CNG system if the CNG tank is reaching an unsafe level of pressure, as might occur with a thermal event that heats up a tank. In the event of a thermal event, the thermal PRD may not vent properly, which increases the likelihood of a CNG tank over-pressurizing and rupturing. A tank rupture creates an increased risk of injury to the truck occupants, firefighters, or bystanders.

 

Affected Vehicles:

The affected vehicle population is PRD valves fitted on tanks assembled by McNeilus between 2013 and 2018 and are PRD valves with serial numbers as found in the attached list.

 

Time Completion:

Affected units shall be inspected using McNeilus qualified service technicians – at no cost to the owner. The time of accomplishment may vary due to a number of factors; however, the estimated time for completion of the procedure is 1.0 hour under normal circumstances.

 

Required Action:

Review and verify the ownership of all affected serial numbers of trucks. If McNeilus records indicate the owner of one or more affected units, a Serial Number List is enclosed. Please be reminded that it is a violation of Federal law for companies to sell or lease the CNG systems or vehicles that use CNG systems covered by this notification until this recall has been performed on these vehicles. Substantial civil penalties apply to violations of this law.

This work instruction is limited to Internal McNeilus Use Only.

 

Contact:

If you have questions or need further information, please contact a National Service Representative at 888-686-7278.

 

Enclosures:

Emcara PRD Valve Inspection Procedure

List of Affected Serial Numbers/Vehicles

 

SAFETY NOTICE

Before entering vehicle’s body or drum or performing maintenance to the vehicle, read and follow OSHA Regulations concerning entry and working in “CONFINED SPACE” OSHA 1910.146 and “LOCKOUT/TAGOUT” OSHA 1910.147.

Follow OSHA Regulations while performing any work to the vehicle.

Follow all safety instructions in your manual.

Shut off truck engine, lock cab doors, and keep keys in your pocket before entering vehicle’s body or drum or performing any work to the vehicle.

Place magnetic “DANGER” signs on both cab doors. Failure to do so can result in serious personal injury or death.

If you have any questions regarding this notice or require further assistance, call McNeilus at 888-686-7278.

 

WARNING

Wear proper Personal Protective Equipment (PPE) such as hard hats, safety glasses or goggles, sturdy gloves, hearing protection, steel toed boots, and snug fitting sturdy long-sleeve shirt and long pants when operating, fueling, defueling, or maintaining the truck.

Reflective clothing is recommended for drivers and employees. Serious personal injury or death can result without proper PPE.

 

WARNING

Use proper fall protection equipment and training when inspecting or maintaining the CNG cylinder on the truck.

Failure to use proper fall protection equipment may result in serious personal injury or death.

 

PROCEDURE: Emcara PRD Valve Serial Number Inspection

Read the entire procedure before beginning.

 

Tools and Equipment Required:

• Bore Scope and micro SD card if you want pictures from the scope
• Emcara Field Inspection Sheet (obtain from your Branch Manager)
• Socket Set
• Small mirror
• Flashlight
• If you want, use the light from your cell phone and take a picture of the serial number. The number may be backwards in the picture.

 

Procedure A: Preparation

1. Place unit on a flat surface, block truck tires, and observe all conditions of the Safety Notice concerning Lockout/Tagout posted in this bulletin. Contact McNeilus Truck and Manufacturing, Inc. at 888-686-7278 if you have any questions.
2. Battery Disconnect Switch

If your vehicle is equipped with a BATTERY DISCONNECT switch, it is located near the battery box. Use the battery disconnect switch when performing any maintenance so the vehicle cannot accidentally be started.

1. 1. Turn the battery disconnect switch (Figure A, Item 1) counterclockwise so the hole on the switch aligns with the hole in the bracket (Figure A, Item 2).
   2. Install the safety lockout device ring (Figure B, Item 1) through the holes on the battery disconnect switch and the bracket.
   3. Install a padlock (Figure B, Item 2) onto the safety lockout device ring, lock it, and put the key in your pocket. If more than one person is working on the vehicle, each person must install his or her own padlock.

Battery Cable Disconnect – No Switch Application If your vehicle is not equipped with a battery disconnect switch, disconnect the negative (black) battery cable first, then disconnect the positive (red) cable.

 

WARNING

For trucks without a battery disconnect switch, to prevent accidental vehicle start-up, which could cause death or serious injury, disconnect battery cables (negative cable first) before proceeding.

Disconnect negative (-) battery cable first. If positive (+) cable should contact ground with negative (-) cable connected, the resulting sparks can cause a battery explosion, which could result in death or serious injury.

3. You must use the proper fall protection equipment when working on this bulletin procedure. Contact McNeilus Truck and Manufacturing, Inc. at 888686-7278 if you have any questions.

 

WARNING

Use proper fall protection equipment and training when inspecting or maintaining the CNG cylinder on the truck.

Failure to use proper fall protection equipment may result in serious personal injury or death.

 

Procedure B: Inspection of the PRD Serial Number

IMPORTANT: Read the entire bulletin before starting the procedure so that you can gather all of the necessary equipment.

Because the CNG system covers will remain on the system, use the bore scope to read the serial number on the label of the PRDs.

 

Tips for using the bore scope:

• If you want the bore scope to take a picture, make sure you have purchased and installed a micro SD card in the bore scope.
• Make sure to bend the bore scope camera to the angle you will need to view the serial number before you insert the bore scope under the CNG cover.
• Practice using the bore scope before you attempt this bulletin procedure.

1. Locate the serial numbers on the PRD valves. Figures 1 through 4 are illustrative representations of the various CNG system configurations and the location of PRDs on those configurations. Use these Figures as your guides to determining the location of the PRDs and where to place the bore scope to read the PRDs.

 

For the Frame Mount: Try determining the serial number by inserting the bore scope through the side access cover opening (follow Figure 1). If you cannot determine the serial number on the PRD using this method, follow the instructions given in Figure 2 and Figure 3 to access the PRD by removing a tank cover.

Illustration represents the access the PRD of a Frame Mount system. Remove the tank cover to access the PRD label. Start by locating the clamps. Remove and retain the cotter pin in the clamps. Open the clamps to free the cover. Take the cover off and bend the bore scope or use a mirror (and flashlight or cell phone light and camera to take a picture) to angle down to read the serial number on the PRD label. Replace the cover and clamp shut to secure the cover.

Illustration represents the location of the PRD valve when the cover is removed on the Frame Mount CNG system.

NOTE: Rear discharge mixers that utilize the Emcara PRD will have one PRD per tank. The 65” tank will be the only tank that does not utilize this style PRD. In that tank design, there will be a single PRD integrated into the manual valve of the tank. As shown above, a twin vertical mount will also have one PRD per tank.

1. If the PRD was fitted on tanks assembled by McNeilus between (and including) 2013 and 2018 and are PRD valves with serial numbers as found in the attached list, the PRD valve will need to be replaced (see Figure 5 for location of serial number on the PRD valve).
2. Inspect each PRD valve on each CNG tank in the CNG system.
3. Obtain the Emcara Field Inspection Sheet from your Branch Manager. Fill out the sheet during the inspection.
4. Give the completed Emcara Field Inspection Sheet to your Branch Manager.

Figure 5: Inspect the serial number on each PRD Valve in the CNG system.

If you have questions on the inspection process, contact McNeilus Truck and Manufacturing, Inc. at 888-686-7278.

 

(888) 686-7278

www.streetsmartparts.com

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Remedy Instructions and TSB

RCRIT-19V656-9597.pdf 1037.024KB

 

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