ENP-734 – Emer PRD Replacement for Gillig CNG Fuel Systems with Type 3 Cylinders and Manual Cylinder Valves

SEOCONTENT-START

5. Corrective Action / Procedure
5.1. Preliminary Safety Preparation
1
Set parking brake and
secure vehicle with wheel
chocks (not shown).
2
Attach a lock and tag (not
shown) to block vehicle
ignition.
WHAT
WHAT
WHY
Worker safety.
WHY
Prevent vehicle start during
repair procedure.
3
Secure a safety ladder in
either of the following
locations:
A. Inside bus hatch
opening
B. Rear of bus exterior
WHY WHAT
Worker safety.
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4 1. Open fuel system roof
pod doors (d).
2. Secure fall protection
equipment (not shown)
to facility fall protection
apparatus or to fall
restraint lanyard
attachment points (2).
3. Secure doors open with
door retention strap (e).
Refer to vehicle OEM
instructions.
4. Always reattach fall PPE
when resuming work on
the roof mount portion of
the fuel system.
WHY WHAT
Worker safety.
1
2
d
e
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5.2. Prior to defueling
1
Verify all eight cylinder
valves (circled) are open.
WHY WHAT
Ensure cylinders can be
properly defueled.
2 Check high pressure
gauge (1) and low
pressure gauge (3) on fuel
management module
(FMM) (2) to verify amount
of fuel in the system.
IMPORTANT: If vehicle
has no fuel onboard,
proceed to Step 10.
WHY WHAT
1 3
2
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3 If not already defueled:
Defuel bus according to
local facility regulations
and procedure.
If required: use defuel
hose kit.
Only trained CNG fuel
systems technicians may
perform system
defueling.
If required: Use
appropriate defuel nozzle
adapter.
4
Relieve any remaining
system pressure by slowly
opening the FMM (2) bleed
valve (not visible). NOTE:
FMM rear view shown.
WHAT
WHAT
WHY
PRD supply tubes to be
removed are pressurized
“live” lines.
WHY
Pressure remains in lines
while gas is present in the
system.
2
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5.3. Remove and replace Emer PRDs
1 1. Use a microfiber towel
and Swagelok® Snoop®
to clean PRD (3), elbow
fitting (1), and nut fitting
(a).
2. Use a wrench to loosen
PRD vent tube nut fitting
(a) on elbow fitting (1).
3. If necessary: Gently
move PRD vent tube (2)
to allow easier access to
PRD (3).
4. If necessary: Loosen
bolt (not visible)
securing dual tube
clamp (4) to allow PRD
vent tube (2) to move.
WHY WHAT
Prevent debris from
entering fuel system.
2
4
a
1
3
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2 1. Use two wrenches to
remove elbow fitting (1)
from PRD (3).
2. Use a wrench to remove
PRD (3).
Do not allow debris to
enter cylinder (5).
3. Place removed Emer™
PRD in zip lock bag
provided with bulk
retrofit kit shipment.
Place only PRDs from
one vehicle in each zip
lock bag.
Bag must be labeled with
the following:
1. Fleet
2. VIN
3. Fuel system s/n
WHY WHAT
1. Bag helps prevent PRD
contamination.
2. Agility is collecting all
PRDs removed; return
material authorization
(RMA) instructions
appear below.
3
1
A
B
3
5
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3 Use a wrench to install
replacement Emer™ PRD,
p/n, (3).
Torque PRD (3) to 140 ftlbs
(190Nm).
4 Use two wrenches to install
elbow fitting (1) on PRD (3).
Torque elbow fitting (1) to
45 ft-lbs (61Nm).
WHAT
WHAT
WHY
WHY
5 1. Use a wrench to tighten
PRD vent tube nut fitting
(a) on elbow fitting (1).
Torque nut fitting (a) to
45 ft-lbs (61Nm).
2. If necessary: Tighten
bolt (not visible)
securing dual tube
clamp (4).
Tighten bolt to 8 ft-lbs
(11Nm).
6 Repeat Steps 1 through 5
until all eight Emer™ PRDs
have been replaced.
WHAT
WHAT
WHY
WHY
3 3
1
3
1
4
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5.4. System Leak Check Procedure
1 1. Turn 1/4-turn manual shut
off valve (1) on the FMM (2)
to the OPEN position.
2. Select the appropriate CNG
fuel nozzle and/or adaptor
for the FMM (2) defuel
receptacle (3).
3. Remove fuel fill receptacle
dust cap (not shown).
4. Begin fueling the vehicle
with CNG using a regulated
fuel supply.
Open nozzle valve slowly
and regulate gas delivery to
prevent connector from icing
and reducing or blocking
fuel flow.
Follow all local and facility
fueling regulations and
procedures.
WHY WHAT
Test fuel system integrity.
1 3 2
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2 Monitor FMM high
pressure gauge to verify
when system pressure
reaches 500 psi to 510
psi (3.45MPa to
3.52MPa) and stop
pressurization.
.⚠
1. If a hissing sound is
heard coming from
fuel system fittings
during filling, stop
the fill immediately.
2. Try to isolate the
sound and spray
Swagelok Snoop®
on the suspected
location to check for
bubble formation.
3
Leak test all fuel and
PRD tubes and fitting
connections using Swagelok
Snoop® leak detection solution
or equivalent.
WHAT
WHAT
WHY
Subjects fuel system to
partial operating
pressure.
WHY
Approved leak detection
solution for visual inspection
of system leaks.
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4 1. Begin at one end of
the fuel system and
work methodically to
spray all fuel line
fittings with Swagelok
Snoop® or equivalent.
2. Allow at least 10
minutes to elapse
before checking the
integrity of fitting
connections.
5 If a leak is audible or icing,
condensation, foam, or
bubbles appear at a fitting
connection the fitting
connection must be
inspected.
Fuel system must be
defueled prior to
investigating any leak.
Refer to OEM procedure to
defuel system.
WHAT
WHAT
WHY
WHY
6 Re-tighten leaking
fitting(s) discovered
during Step 5.
Refer to fitting type
and size specific
tightening
specifications.
7 Repeat Steps 1 and 2 to
repressurize the system.
WHAT
WHAT
WHY
WHY
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8 Spray leaking fitting
again with Swagelok
Snoop® or equivalent
and allow at least 10
minutes to elapse before
checking for bubble
formation.
9
If leaking fitting is fixed,
proceed to test any remaining
fitting connections.
WHAT
WHAT
WHY
WHY
10
If leak is not fixed, the
fuel system must be
defueled to replace the
fitting.
Perform OEM defuel
procedure.
11 Inspect tubing, fittings,
ferrules, and nuts at the site of
the leak for perforations,
cracks, assembly defects, or
other damage.
Any damaged components
must be replaced.
WHAT
WHAT
WHY
WHY
12 Replace any related
components at the fitting
junction as required.
13 Repressurize fuel system by
repeating Step 1 and Step 2.
WHAT
WHAT
WHY
WHY
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14
Spray new fitting
junction with Swagelok
Snoop® or equivalent to
retest for leaks.
15 Turn FMM 1/4-turn manual
shut off valve (3)
counterclockwise to the
OPEN position.
WHAT
WHAT
WHY
WHY
Allow fuel into system.
16
Repeat pressure
test procedure stopping
the fill when fuel system
pressure reaches 2000
psi to 2100 psi
(13.79MPa to
14.48MPa).
17
Repeat pressure test
procedure stopping the fill
when fuel system pressure
reaches 3600 psi to 3700 psi
(24.8MPa to 25.5MPa) and
repeat leak checking all
connections until entire fuel
system is confirmed leak free.
WHAT
WHAT
WHY
Subjects fuel system to
partial operating
pressure.
WHY
Subjects fuel system to full
operating pressure.
18
If fuel system is leak
free or if defueling is
required, close flow
valve on CNG dispense
nozzle (not shown) and
carefully disconnect fill
nozzle (not shown) from
FMM (2) defuel
receptacle (3).
19 Replace dust cap (not shown)
on FMM defuel receptacle.
WHAT
WHAT
WHY
WHY
Vehicle will not start if dust
cap is not in place.
2
3
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20 If not open, turn FMM
(2) 1/4-turn manual shut
off valve (1)
counterclockwise to the
OPEN position.
21
Clean Swagelok® Snoop® or
equivalent from the fuel
system.
WHAT
WHY
Allow gas to flow
throughout fuel system.
WHY
Customer satisfaction.
22
When the pressure test
is completed
successfully, use form
FT.0322 (c) to record
the result and the date
on which the fuel system
passed the 3600 psi
test.
23 Apply Torque Seal to all fitting
junctions.
WHAT
WHY
Verify safe and proper
fuel system pressure
specification.
System quality specification.
1
2
c
b
a
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24
Use a blue paint marker
to mark a stripe (a) on
all eight PRDs (3)
replaced.
WHAT
WHY
Easily identify replaced
PRDs.
3
a
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5.5. Reporting and Return Procedure
1 1. Use form FT.0322
(c) to record the
Date of Manufacture (a)
and batch number (b)
and the location of each
replacement PRD (16),
p/n 10301046, within the
fuel system.
2. Inspect fuel system
repairs per the quality
assurance criteria
specified in FT.0322.
Use a flashlight to aid
serial number identification
in low light.
3. Use a camera or
camera phone to take a
photo of completed form
FT.0322 (c).
4. Submit photo of
completed form FT.0322
(c) to the email address
indicated on the form to
receive a Return
Material Authorization
(RMA) shipping label.
WHY WHAT
Required for retrofit kit
component and repair
tracking and, if applicable,
installer reimbursement.
c
b
a
16
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2 Repeat Section 5.
Corrective Action /
Procedure for all vehicles
subject to the Emer™ PRD
recall on hand until all
repairs are complete.
3
1. Pack all removed PRDs
(still bagged by VIN), in one
box. If the quantity of PRDs
is too large for a single box,
use additional boxes but
ship them all using the
same RMA.
If possible: reuse the box in
which the replacement
PRDs were shipped.
2. Apply RMA label obtained
from Agility® to the box.
3. Use a permanent marker to
write RMA number on
exterior of each shipping
box.
WHAT
WHAT
WHY
WHY
Required for repair return
tracking and, if applicable,
installer reimbursement.
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6. Warranty Information
This procedure is covered under warranty. Standard repair time (SRT) is TBA. Please refer
to Warranty Manual, ENP-067, for warranty reimbursement procedures.
For parts and support, contact Agility Fuel Solutions Customer Care:
+1 949 267 7745
toll free: +1 855 500 2445
[email protected]
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versions, including updates and revisions forwarded separately, are proprietary. The
information provided by Agility® to its customers and clients is solely for the use of those
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Agility® Fuel Solutions | 3335 Susan Street Suite 100 | Costa Mesa, CA 92626 USA
www.agilityfuelsolutions.com
Revision Description Author Approved By Date
— Initial Release C. Grasso CCG Team 05/27/2020