ENP-740 – Emer PRD Replacement for Gillig CNG Fuel Systems with Type 4 Cylinders and Electric Solenoid Cylinder Valves – Agility

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.
ENP-740 REV A 8/5/2020 (Printed and downloaded copies are uncontrolled) 9 of 90
4 1. Open fuel system roof
pod doors (d).
2. Secure fall protection
equipment to facility fall
restraint equipment (not
shown).
If no fall restraint is
present at the facility,
secure fall protection
equipment (not shown)
to fall restraint lanyard
attachment points (2).
3. Secure doors open with
door retention strap (e).
Refer to vehicle OEM
instructions.
Always reattach fall PPE
when resuming work on
the roof mount portion of
the fuel system.
WHY WHAT
Fall safety.
1
2
d
e
ENP-740 REV A 8/5/2020 (Printed and downloaded copies are uncontrolled) 10 of 90
5.2. Prior to defueling
1
Verify all eight cylinder
valves (circled) are open.
WHY WHAT
Ensure cylinders can be
properly defueled.
2 1. Check high pressure
gauge (3) on fuel
management module
(FMM) (4) to verify
amount of fuel in the
system.
2. Verify FMM (4) 1/4-turn
manual shut off valve
(5) is in the OPEN
position.
IMPORTANT: If vehicle
has no fuel onboard,
proceed to Step 4.
WHY WHAT
4
3
5
ENP-740 REV A 8/5/2020 (Printed and downloaded copies are uncontrolled) 11 of 90
3 If not already defueled:
Defuel bus according to
Agility publication ENP-
729.
Always follow local
facility regulations and
procedure for defueling.
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 (4) bleed
valve (b).
WHAT
WHAT
WHY
PRD supply tubes to be
removed are pressurized
“live” lines.
WHY
b
4
ENP-740 REV A 8/5/2020 (Printed and downloaded copies are uncontrolled) 12 of 90
5.3.1. Mark Emer™ valve end PRDs, Emer™ p/n PRD2102T
1 A. Use a microfiber towel
and water to clean
solenoid cylinder valve
(3) and valve PRD (1)
surfaces.
B. Dry the solenoid cylinder
valve (3) and valve PRD
(1).
C. When the PRD is clean
and dry: Use a
permanent marker or
paint marker to legibly
write the serial number
(a) and batch number
(b) from the solenoid
cylinder valve (3) on the
valve PRD (1) as
indicated by the
example (circled).
WHY WHAT
Recall reporting mandates
recording serial number
and batch number data.
1
3
a
b
Solenoid coil (c) color may
vary from illustration.
c
ENP-740 REV A 8/5/2020 (Printed and downloaded copies are uncontrolled) 13 of 90
2
Use form FT.0323 (d) to
record the following data
for each Emer™ valve
PRD (1):
Serial number (a)
Batch number (b)
3 Repeat Steps 1 and 2 until all
valve PRDs have been
marked.
WHAT
WHAT
WHY
Required for retrofit kit
component and repair
tracking and, if applicable,
installer reimbursement.
WHY
d
a
b
ENP-740 REV A 8/5/2020 (Printed and downloaded copies are uncontrolled) 14 of 90
5.3.2. Remove and replace Emer™ valve end PRDs, Emer™ p/n PRD2102T
Refer to Appendix C: “OEM Emer Instruction PRD Manual to Replace the PRD” (below) for installation details.
Always perform installation steps in the order specified.
1 A. Use a wrench to loosen
dual tube clamp (8)
fasteners (not visible) to
aid in moving PRD vent
tube (6) aside but do not
remove.
B. Use a pair of wrenches
to disconnect PRD vent
tube (6) nut fitting (a)
from PRD (1) elbow
fitting (7).
Avoid damage to
pressure transducer (d)
and high pressure fuel
tube (e).
WHY WHAT
6 1
7
d
8
e
ENP-740 REV A 8/5/2020 (Printed and downloaded copies are uncontrolled) 15 of 90
3 Use a wrench to loosen
jamb nut (b) of elbow fitting
(7) while holding PRD (1)
with another wrench at
PRD flats (a).
WHY WHAT
1
7 a
b
a
ENP-740 REV A 8/5/2020 (Printed and downloaded copies are uncontrolled) 16 of 90
4
Remove and replace one
PRD at a time to avoid
system contamination.
1.Use a 15/16-in. angled
open end wrench
(Tekton® p/n WAE83024)
(a) OR a modified 1/2-in.
drive 24mm deep socket
(b) and ratchet to remove
PRD (1) from valve (3).
Avoid contact with
pressure transducer (d).
2. Place PRD (1) removed
in a zip lock bag.
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
Agility® collects all PRDs
removed.
1
d
3
a
b
ENP-740 REV A 8/5/2020 (Printed and downloaded copies are uncontrolled) 17 of 90
5 1. Use Swagelok® Snoop®
a microfiber towel to
clean and inspect valve
body (3) PRD port
threads and O-ring
surfaces (not visible).
2. Use Swagelok® Snoop®
and a microfiber towel to
remove old Torque Seal
from fitting junction (not
shown).
3. Apply a light film of
Parker® O-lube O-ring
lube to replacement
PRD (5) O-ring (4).
4. Verify O-ring (4) is
properly seated.
5. Apply Loctite® 276 to
PRD (5) threads (a).
WHY WHAT
Emer™ specification.
4
5
a
3
ENP-740 REV A 8/5/2020 (Printed and downloaded copies are uncontrolled) 18 of 90
6 Install PRD (5) on valve
body (3) using a 15/16-in.
angled open end wrench
(Tekton® p/n WAE83024)
(a) or a modified 1/2-in.
drive 24mm deep socket
(b) and ratchet (not
shown).
Torque PRD (5) to 30Nm
(22 ft-lbs).
7 1. Move jamb nut (b) to base
(c) of elbow fitting (7).
2. Use a wrench to install
elbow fitting (7) on PRD
(1).
3. Use a wrench to hold PRD
(1) at PRD flats (a).
4. Position elbow fitting (7) to
line up with PRD vent tube
(not shown).
5. Tighten elbow fitting jam
nut (b).
Torque elbow fitting jam
nut (b) to 45 ft-lbs (61Nm).
WHAT
WHAT
WHY
System specification.
WHY
System specification.
3
5
a
b
7 b
c a
a
ENP-740 REV A 8/5/2020 (Printed and downloaded copies are uncontrolled) 19 of 90
8 Use a pair of wrenches to
install PRD vent tube (6)
nut fitting (a) on elbow
fitting (7).
Torque elbow fitting (7)
jam nut (b) to 45 ft-lbs
(61Nm).
9 Repeat Steps 1 through 8
until all eight valve end PRDs
have been replaced.
Do not tighten PRD vent
tube clamps (8); clamps will
be tightened later.
WHAT
WHAT
WHY
System specification.
WHY
6
a
7
8
ENP-740 REV A 8/5/2020 (Printed and downloaded copies are uncontrolled) 20 of 90
5.4. Remove Emer™ remote PRDs, Emer™ p/n PRD2302T-004
1 1.Use two wrenches to
loosen nut fittings (a) on
each Emer™ PRD (d).
2.Use wrenches to remove
fasteners securing the
following items:
A. P-clip (7)
B. Dual tube clamp (8)
C. Plate (6)
Retain all clips,
clamps, plates and
fasteners for reuse.
▪ Support PRD and PRD
vent assembly while
removing clips and
clamps.
▪ Use caution to avoid
contact with cylinders
or PRD supply tube (f).
3. Carefully remove
Emer™ PRDs (d) and
PRD vent tubes (5a)
and (5b) from each PRD
bracket (9) as complete
assemblies.
4. Repeat for all plug end
cylinders on all roof
mount pods.
WHY WHAT
Protect cylinders from
damage.
7
6
7
6
d
d
9
8
8
a
d
NOTE: 85-in. cylinder end of
system shown; 120-in. similar.
5a
5b
9
ENP-740 REV A 8/5/2020 (Printed and downloaded copies are uncontrolled) 21 of 90
2 Use a pair of wrenches to
remove all Emer™ PRDs
(d) from PRD vent tubes
(5a) and (5b).
Dispose of PRD vent
tubes (5a) and (5b)
according to facility
guidelines.
3 Use form FT.0323 (c)
to record the following
data for each Emer™ PRD
(d) removed:
A. Date of Manufacture (a)
B. Batch number (b)
WHAT
WHAT
WHY
PRD vent tubes will not be
reused.
WHY
Required for retrofit kit
component and repair
tracking and, if applicable,
installer reimbursement.
5a
d
5b
d
c
a
b
ENP-740 REV A 8/5/2020 (Printed and downloaded copies are uncontrolled) 22 of 90
4 Place all removed Emer™
PRDs 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
WHAT
WHY
1. Bag helps prevent PRD
contamination.
2. Agility is collecting all
PRDs removed; return
material authorization
(RMA) instructions
appear below.
ENP-740 REV A 8/5/2020 (Printed and downloaded copies are uncontrolled) 23 of 90
5.5. Install PRD retrofit kits
5.5.1. Kit, Retrofit, Gillig, 85″ tanks PRD Retrofit, p/n 25519030, installation instructions
Always perform installation steps in the order specified.
1 1. Install ferrules (not
visible) and nut (a) from
tee fitting (12), p/n
10200208, on PRD
tube, (13), p/n
25519417.
2. Install ferrules (not
visible) and nut (b) from
tube fitting (14), p/n
10200065, on PRD
tube, (13).
3. Install ferrules (not
visible) and nut (c) from
tee fitting (12), p/n
10200208, on tube
adapter fitting, (17), p/n
10200238.
Refer to Appendix A:
WI.0197 Manual Swaging
of Swagelok Fittings.
WHY WHAT
a
13
b
12
14
c
17 85-in. cylinder pod
ENP-740 REV A 8/5/2020 (Printed and downloaded copies are uncontrolled) 24 of 90
2 1. Install tee fitting (12), p/n
10200208, on PRD
tube, (13).
Tighten fitting finger
tight; fittings will be
tightened at a later step.
2. Install two tube clamp
kits (15), p/n 10701508,
on PRD tube, (13).
3. Insert one 1.5-in. hex
cap screw (a), p/n
10760200-0150, and
one 2.5-in. hex cap
screw (b), p/n
10760200-0120, into
each tube clamp kit (15),
as shown in INSET A.
4. Install one flat washer,
p/n 10761000, and one
flange top nut, p/n
10763000 (not shown)
on each hex cap screw
inserted.
5. Secure clamps (15) at
existing holes (circled)
on PRD bracket (9).
To ease component
installation, leave
fasteners loose.
WHY WHAT
Support PRD vent lines.
13 15
9
12
INSET A
85-in. cylinder pod
ENP-740 REV A 8/5/2020 (Printed and downloaded copies are uncontrolled) 25 of 90
3 Install PRD supply tube
(5c) nut fitting (a) at tee
fitting (12) of PRD tube
(13).
Tighten fitting finger
tight; fitting will be
torqued at a later step.
WHY WHAT
5c
13
12
85-in. cylinder pod
a
ENP-740 REV A 8/5/2020 (Printed and downloaded copies are uncontrolled) 26 of 90
4
Always use a
backing wrench on the
main fitting while using a
wrench to install another
fitting.
1. Install tube adapter
fitting (17), p/n
10200238 on VTI PRD
(16b), p/n 10300513.
Torque fitting (17)
to 26 ft-lbs
(35.25Nm)
2. Install straight fitting
(18), p/n 10200563, on
VTI PRD (16a), p/n
10300513.
3. Install straight fitting
(18), p/n 10200563, on
VTI PRD (16a), p/n
10300513.
Torque fittings (18)
to 18.5 ft-lbs
(25Nm).
4. Install tube fitting (14),
p/n 10200065, on VTI
PRD (16a), p/n
10300513.
Torque fitting (14)
to 45 ft-lbs (61Nm).
WHY WHAT
16a
14 17
18 16b 18
85-in. cylinder pod
ENP-740 REV A 8/5/2020 (Printed and downloaded copies are uncontrolled) 27 of 90
5 1. Install VTI PRD (16a)
assembly inlet fitting (a)
on PRD supply tube
(13) at tee fitting (12).
2. Install VTI PRD outlet
fitting (16b) on straight
fitting (b) on other end of
PRD supply tube (13).
Tighten fittings finger
tight; fittings will be
torqued at a later step.
PRD ports (c) must
be oriented 90°
down from the flow of
system tubing as shown.
WHY WHAT
a b
16a 16b
13
12
85-in. cylinder pod
c c
ENP-740 REV A 8/5/2020 (Printed and downloaded copies are uncontrolled) 28 of 90
6a 1. Install PRD vent tube
(26), p/n 25519026, on
PRD (16a) fitting (a).
Tighten nut fitting finger
tight; fittings will be
tightened at a later step.
2. Slip dual tube clamp (8),
on PRD vent tube (26),
and on PRD vent tube
(5a).
3. Use dual tube clamp (8)
fasteners (not visible) to
secure plate (6) and
PRD vent tube (26), to
PRD bracket (9) at hole
(circled).
4. Slide P-clip on PRD vent
tube (26) and use
existing fastener to
secure P-clip (7) to Pclip
bracket (b).
Tighten fasteners finger
tight; fasteners will be
torqued at a later step.
WHY WHAT
5c
8
7
b
26
a
16a
6
85-in. cylinder pod
ENP-740 REV A 8/5/2020 (Printed and downloaded copies are uncontrolled) 29 of 90
6b 1. Install PRD vent tube
(37), p/n 25519037, on
PRD (16b) fitting (a).
Tighten nut fitting (b)
finger tight; fitting will be
tightened at a later step.
2. Slip tube clamp kit (15),
on PRD vent tube (37).
3. Insert one 1.5-in. hex
cap screw, p/n
10760200-0150, and
one 2.5-in. hex cap
screw, p/n 10760200-
0120, into each tube
clamp kit (15), as shown
in INSET A.
4. Install one flat washer,
p/n 10761000, and one
flange top nut, p/n
10763000 (not shown)
on each hex cap screw
inserted in previous sub
step.
5. Secure PRD vent tube
(37) to PRD bracket (9)
at existing hole.
Tighten fasteners finger
tight; fasteners will be
torqued at a later step.
WHY WHAT
37
a 15 16b
INSET A
2.5-in. HEX CAP SCREW FACES TOWARD
PRD BRACKET (9) TO SECURE CLAMP
(15) TO PRD BRACKET.
1.5-in. HEX CAP SCREW FACES AWAY
FROM PRD BRACKET TO CAPTURE
CLAMP (15).
15
b
85-in. cylinder pod
ENP-740 REV A 8/5/2020 (Printed and downloaded copies are uncontrolled) 30 of 90
7 1. Install tube clamp
bracket (23), p/n
25519123, on existing
double tube clamp (8)
using the double tube
clamp fasteners.
2. Install P-clip (7), p/n
10702147, on PRD vent
tube (37), p/n 25519037,
and secure to bracket
(23), p/n 25519123
using one hex cap
screw, p/n 10760200-
0100, one flat washer,
p/n 10761000, and one
flange top nut, p/n
10761300.
Tighten fasteners finger
tight; fasteners will be
tightened at a later step.
WHY WHAT
System specification.
VIEW A
VIEW A
23
8
37 85-in. cylinder pod
7
ENP-740 REV A 8/5/2020 (Printed and downloaded copies are uncontrolled) 31 of 90
8a Use two wrenches to
tighten 1/2-in.
Swagelok® fitting
nuts indicated in the
following sequence:
1. (a)
2. (b)
3. (c)
4. (d)
Tighten 1/2-in.
Swagelok® fittings per
Appendix B WI.0441.
WHY WHAT
System specification.
8b Use two wrenches to
tighten SAE / JIC
fitting nuts at the locations
indicated in the following
sequence:
1. (e)
2. (f)
Tighten SAE / JIC fittings
to 45 ft-lbs (61Nm).
WHY WHAT
System specification.
b a 85-in. cylinder pod
d
c
85-in. cylinder pod
f e
ENP-740 REV A 8/5/2020 (Printed and downloaded copies are uncontrolled) 32 of 90
9 Tighten clamp
fasteners at all
clamp locations (circled)
using the following
sequence:
1. (a)
2. (b)
3. (c)
4. (d)
5. (e)
6. (f)
Tighten fasteners to 8 ftlbs
(11Nm).
WHY WHAT
System specification.
Proper tightening
sequence is crucial to
system performance.
85-in. cylinder pod
a b c
d
e
f
ENP-740 REV A 8/5/2020 (Printed and downloaded copies are uncontrolled) 33 of 90
10 1. Verify clearance
between PRD vent
tubes (a), live high
pressure PRD vent tubes
(b), and fuel tubes (c) is
3/8-in. minimum.
2. Verify clearance
between all system
plumbing and cylinders (c)
is 3/8-in. minimum.
If required: Adjust tube
clips and clamps as
required and repeat Step
10.
WHY WHAT
Prevent fuel line damage.
b
b
a
c
85-in. cylinder pod
NOTE: Plug end shown for
reference; valve end similar
ENP-740 REV A 8/5/2020 (Printed and downloaded copies are uncontrolled) 34 of 90
11 1. Install ferrules (not
visible) and nut (a) from
tee fitting (12), p/n
10200208, on PRD vent
tube, (13), p/n
25519417.
2. Install ferrules (not
visible) and nut (b) from
tube fitting (14), p/n
10200065, on straight
end of PRD vent tube
(13).
3. Install ferrules (not
visible) and nut (c) from
tee fitting (12), p/n
10200208, on tube
adapter fitting, (17), p/n
10200238.
Refer to Appendix A:
WI.0197 Manual Swaging
of Swagelok Fittings.
4. Install tee fitting (12),
p/n 10200208, on PRD
vent tube (13), p/n
25519417.
Tighten fitting finger
tight; fittings will be
tightened at a later step.
WHY WHAT
b
13
12
14
a
12
17 c
85-in. cylinder pod
ENP-740 REV A 8/5/2020 (Printed and downloaded copies are uncontrolled) 35 of 90
12 1. Install two tube clamp
kits (15), p/n 10701508,
on Tube, Formed, HP
Fuel, 1/2-in. X .049 -in.,
Tee to PRD, (13), p/n
25519417.
2. Insert one 1.5-in. hex
cap screw, p/n
10760200-0150, and
one 2.5-in. hex cap
screw, p/n 10760200-
0120, into each tube
clamp kit (15), as shown
in INSET A.
3. Install one flat washer,
p/n 10761000, and one
flange top nut, p/n
10763000 (not shown)
on each hex cap screw
inserted in previous sub
step.
4. Secure PRD vent tube
(13) to PRD bracket (9)
at existing holes
(circled).
To ease component
installation, do not
tighten fasteners
completely; fasteners
will be torqued at a later
step
WHY WHAT
Support PRD vent lines.
15
13
9
INSET A
15
2.5-in HEX CAP SCREW FACES TOWARD PRD BRACKET
(9) TO SECURE CLAMP (15) TO PRD BRACKET.
1.5-in HEX CAP SCREW FACES AWAY FROM
PRD BRACKET (9) TO CAPTURE CLAMP (15).
85-in. cylinder pod
ENP-740 REV A 8/5/2020 (Printed and downloaded copies are uncontrolled) 36 of 90
13 Install PRD supply tube (5b)
on tee fitting (12) on PRD
supply tube (13).
Tighten fitting finger tight;
fitting will be tightened at
a later step.
WHY WHAT
5b
13
12 85-in. cylinder pod
ENP-740 REV A 8/5/2020 (Printed and downloaded copies are uncontrolled) 37 of 90
14
Always use a
backing wrench on the
main fitting while using a
wrench to install another
fitting.
5. Install tube adapter
fitting (17), p/n
10200238 on VTI PRD
(16b), p/n 10300513.
Torque fitting (17)
to 26 ft-lbs
(35.25Nm)
6. Install straight fitting
(18), p/n 10200563, on
VTI PRD (16a), p/n
10300513.
7. Install straight fitting
(18), p/n 10200563, on
VTI PRD (16a), p/n
10300513.
Torque fittings (18)
to 18.5 ft-lbs
(25Nm).
8. Install tube fitting (14),
p/n 10200065, on VTI
PRD (16a), p/n
10300513.
Torque fitting (14)
to 45 ft-lbs (61Nm).
WHY WHAT
16a
14 17
18 16b 18
85-in. cylinder pod
ENP-740 REV A 8/5/2020 (Printed and downloaded copies are uncontrolled) 38 of 90
15 1. Install VTI PRD (16a)
assembly inlet fitting (a)
on PRD supply tube
(13) at tee fitting (12).
2. Install VTI PRD outlet
fitting (16b) on straight
fitting (b) on other end of
PRD supply tube (13).
Tighten fittings finger
tight; fittings will be
torqued at a later step.
PRD ports (c) must
be oriented 90°
down from the flow of
system tubing as shown.
WHY WHAT
a b
16a 16b
13
12
85-in. cylinder pod
c c
ENP-740 REV A 8/5/2020 (Printed and downloaded copies are uncontrolled) 39 of 90
16 1. Install PRD vent tube
(27), p/n 25519027, on
PRD (16a) fitting (a).
Tighten fittings finger
tight; fittings will be
torqued at a later step.
2. Use dual tube clamp, (8)
and plate (6), to secure
PRD supply tube (5d) to
PRD vent tube (27).
3. Secure dual tube clamp
(8) to PRD bracket (9) at
existing hole.
4. Slip P-clip (7) on PRD
vent tube (27).
5. Attach P-clip (7) to Pclip
bracket (b) using
existing fasteners (not
visible).
Tighten fasteners finger
tight; fasteners will be
torqued at a later step.
WHY WHAT
a
6
9
8
5d 16a
27
b
7 27
85-in. cylinder pod
ENP-740 REV A 8/5/2020 (Printed and downloaded copies are uncontrolled) 40 of 90
17
a
Use two wrenches to
tighten 1/2-in.
Swagelok® nut fittings at
four locations (circled) in
the following sequence:
1. (a)
2. (b)
3. (c)
4. (d)
Tighten Swagelok® nut
fittings per Appendix B
WI.0441.
WHY WHAT
System specification.
85-in. cylinder pod
a
b
d
c
ENP-740 REV A 8/5/2020 (Printed and downloaded copies are uncontrolled) 41 of 90
17
b
A. Use two
wrenches to tighten
SAE / JIC nut fittings at
two locations (circled) in
the following sequence:
1. (e)
2. (f)
Tighten SAE / JIC nut
fittings to 45 ft-lbs
(61Nm).
B. Verify vent ports
of VTI PRDs (16a)
and (16b) are
pointed down (arrows).
WHY WHAT
System specification.
85-in. cylinder pod
e f
16a 16b
ENP-740 REV A 8/5/2020 (Printed and downloaded copies are uncontrolled) 42 of 90
18 1. Install tube clamp
bracket (23), p/n
25519123, existing
double tube clamp (7)
using double tube clamp
fasteners (not shown).
2. Install P-clip (7), p/n
10702147 on PRD vent
tube (37), p/n 25519037.
3. Install P-clip (8) on tube
clamp bracket (23) using
one hex cap screw, p/n
10760200-0100, one flat
washer, p/n 10761000,
and one flange top nut,
p/n 10761300.
Tighten fasteners finger
tight; fasteners will be
tightened at a later step.
WHY WHAT
PRD vent tubes may need
to be adjusted for
clearance.
23
85-in. cylinder pod
7
23
8
37
ENP-740 REV A 8/5/2020 (Printed and downloaded copies are uncontrolled) 43 of 90
19 Tighten fasteners at
clamp and clip
locations (circled) using
the following sequence:
1. (a)
2. (b)
3. (c)
4. (d)
5. (e)
6. (f)
Tighten fasteners to 8 ftlbs
(11Nm).
WHY WHAT
System specification.
85-in. cylinder pod
d
e f c b a
ENP-740 REV A 8/5/2020 (Printed and downloaded copies are uncontrolled) 44 of 90
20 1. Verify clearance
between PRD vent
tubes (a) and live high
pressure PRD supply
tubes (b) is 3/8-in.
minimum.
2. Verify clearance
between all system
plumbing and cylinders (c)
is 3/8-in. minimum.
If required: Adjust
clamps as required and
repeat Step 20.
WHY WHAT
Prevent fuel line damage.
b
c
a
NOTE: Plug end shown for
reference; valve end similar.
85-in. cylinder pod
ENP-740 REV A 8/5/2020 (Printed and downloaded copies are uncontrolled) 45 of 90
21 Apply two Decal,
System, Danger Live
High Pressure PRD Line (a),
p/n 10602157, to PRD
supply tubes as indicated.
WHY WHAT
Operator and first
responder safety.
22 Apply four Decal,
PRD Vent Line,
Caution (b), p/n 10602442,
to midpoint of PRD vent
tubes as indicated.
WHY WHAT
Operator and first
responder safety.
a
a
a
85-in. cylinder pod
b
b
b
b
b
85-in. cylinder pod
ENP-740 REV A 8/5/2020 (Printed and downloaded copies are uncontrolled) 46 of 90
5.5.2. Kit, Retrofit, Gillig, 120″ tanks PRD Retrofit, p/n 25519031, installation instructions
Always perform installation steps in the order specified.
1 Use a 5/16-in. drill
bit to drill one
mounting hole at the
midpoint (DETAIL A) of
each of the 120-in. PRD
brackets (9).
While drilling, carefully
place a section of a
wood 2×4 behind the
hole location to prevent
cylinder damage.
WHY WHAT
Additional mounting holes
are required to secure
clamps to support PRD
vent system.
9
NOTE 1: All dimensions provided in inches.
NOTE 2: Not to scale.
120-in. cylinder pod
ENP-740 REV A 8/5/2020 (Printed and downloaded copies are uncontrolled) 47 of 90
2 1. Install ferrules (not
visible) and nut (a) from
tee fitting (12), p/n
10200208, on PRD vent
tube (13), p/n 25519416.
2. Install ferrules (not
visible) and nut (b) from
tube fitting (14), p/n
10200065, on straight
end of PRD vent tube
(13).
3. Install ferrules (not
visible) and nut (c) from
tee fitting (12), p/n
10200208, on tube
adapter fitting, (17), p/n
10200238.
Refer to Appendix A:
WI.0197 Manual Swaging
of Swagelok Fittings.
4. Install tee fitting (12),
p/n 10200208, on PRD
vent tube, (13), p/n
25519416.
Tighten fitting finger
tight; fitting will be
tightened at a later step.
WHY WHAT
a
13
14
12
b
17
c
12 13
14
120-in. cylinder pod
ENP-740 REV A 8/5/2020 (Printed and downloaded copies are uncontrolled) 48 of 90
3 1. Install two tube clamp
kits (15), p/n 10701508,
from retrofit kit on PRD
tube, (13), p/n
25519417.
2. Insert one 1.5-in. hex
cap screw (a), p/n
10760200-0150, and
one 2.5-in. hex cap
screw (b), p/n
10760200-0120, into
each tube clamp kit (15),
as shown in INSET A.
3. Install one flat washer,
p/n 10761000, and one
flange top nut, p/n
10763000 (not shown)
on each hex cap screw
inserted in previous sub
step.
4. Secure PRD vent tube
(13) to PRD bracket (9)
at existing holes
(circled).
To ease component
installation, do not
tighten fasteners
completely; fasteners
will be tightened at a
later step.
WHY WHAT
Support PRD tube.
15
13
9
120-in. cylinder pod
ENP-740 REV A 8/5/2020 (Printed and downloaded copies are uncontrolled) 49 of 90
4 1. Install PRD vent supply
tube (5d) nut fitting (a)
on tee fitting (12) on
PRD tube (13).
Tighten fitting (a) finger
tight; fitting will be
tightened at a later step.
WHY WHAT
5d
13
12
120-in. cylinder pod
a
ENP-740 REV A 8/5/2020 (Printed and downloaded copies are uncontrolled) 50 of 90
5
Always use a
backing wrench on the
main fitting while using a
wrench to install another
fitting.
1. Install tube adapter
fitting (17), p/n
10200238 on VTI PRD
(16b), p/n 10300513.
Torque fitting (17)
to 26 ft-lbs
(35.25Nm)
2. Install straight fitting
(18), p/n 10200563, on
VTI PRD (16a), p/n
10300513.
3. Install straight fitting
(18), p/n 10200563, on
VTI PRD (16a), p/n
10300513.
Torque fittings (18)
to 18.5 ft-lbs
(25Nm).
4. Install tube fitting (14),
p/n 10200065, on VTI
PRD (16a), p/n
10300513.
Torque fitting (14)
to 45 ft-lbs (61Nm).
WHY WHAT
16a
14 17
18 18
120-in. cylinder pod
16b
ENP-740 REV A 8/5/2020 (Printed and downloaded copies are uncontrolled) 51 of 90
6 1. Install VTI PRD (16a)
assembly inlet fitting (a)
on PRD supply tube
(13) at tee fitting (12).
2. Install VTI PRD (16b)
outlet fitting (b) on
straight end of PRD
supply tube (13).
Tighten fittings finger
tight; fittings will be
torqued at a later step.
WHY WHAT
a 13 b
9
12 16a
16b
120-in. cylinder pod
ENP-740 REV A 8/5/2020 (Printed and downloaded copies are uncontrolled) 52 of 90
7 1. Install PRD vent tube
(28), p/n 25519028, on
tee fitting (12).
Tighten fittings finger
tight; fittings will be
tightened at a later step.
2. Install two Tube Clamp
Kits, 1/2-in., Double
Mounting Hole (7), p/n
10701508, from retrofit
kit on PRD vent tube
(28), and PRD supply
tube (5c).
3. Use dual tube clamp (7)
fasteners (not visible)
from to secure clamps to
PRD bracket (9) at
existing holes.
Tighten fasteners finger
tight; fasteners will be
tightened at a later step.
8 1. Slip P-clip (8) removed
earlier on PRD vent tube
(28), p/n 25519028.
2. Secure P-clip (8) to P-clip
bracket (b) using existing
hardware.
Tighten fasteners finger
tight; fasteners will be
tightened at a later step.
WHAT
WHAT
WHY
WHY
12
5c
28 7
9
120-in. cylinder pod
28
8 b
120-in. cylinder pod
ENP-740 REV A 8/5/2020 (Printed and downloaded copies are uncontrolled) 53 of 90
9 1. Install nut fitting of PRD
vent tube (37) on VTI
PRD (16a) outlet fitting
(a).
Tighten fitting finger
tight; fitting will be
tightened at a later step.
2. Install tube clamp kit
(15), p/n 10701508, on
PRD vent tube (37).
3. Use tube clamp kit (15)
fasteners (not visible)
from to secure clamp to
PRD bracket (9) at
existing hole using
clamp kit fasteners as
shown in INSET A.
Tighten fasteners finger
tight; fasteners will be
tightened at a later step.
WHY WHAT
15 9 16a 37
120-in. cylinder pod
a
ENP-740 REV A 8/5/2020 (Printed and downloaded copies are uncontrolled) 54 of 90
10 1. Use two wrenches to
tighten Swagelok® nut
fittings in the following
sequence:
1. (a)
2. (b)
3. (c)
Tighten Swagelok®
fittings per Appendix
B WI.0441.
2. Use two wrenches to
tighten SAE / JIC fitting
nuts in the following
sequence:
1. (d)
2. (e)
Torque SAE / JIC
fittings to 45 ft-lbs
(61Nm).
3. Verify vent ports (f) of
VTI PRDs (16a) and
(16b) are pointed down
(arrows).
WHY WHAT
System specification.
a
b
d e
120-in. cylinder pod
16b 16a
f
f
c
ENP-740 REV A 8/5/2020 (Printed and downloaded copies are uncontrolled) 55 of 90
11 1. Install tube clamp
bracket (23), p/n
25519123, on existing
double tube clamp (8)
using double tube clamp
fasteners (not shown).
Tighten fasteners finger
tight; fasteners will be
tightened at a later step.
2. Slip P-clip (7), p/n
10702147, on PRD vent
tube (37), p/n
25519037.
3. Install P-clip (7) on tube
clamp bracket (23), p/n
25519123, using one
hex cap screw, p/n
10760200-0100, one flat
washer, p/n 10761000,
and one flange top nut,
p/n 10761300.
WHY WHAT
System specification.
7
23
8
120-in. cylinder pod
37
ENP-740 REV A 8/5/2020 (Printed and downloaded copies are uncontrolled) 56 of 90
12 Tighten clamp
fasteners at all
clamp locations (circled)
using the following
sequence:
1. (a)
2. (b)
3. (c)
4. (d)
5. (e)
6. (f)
7. (g)
Tighten fasteners to 8 ftlbs
(11Nm).
WHY WHAT
System specification.
Proper tightening
sequence is crucial to
fuel system integrity.
120-in. cylinder pod
f
a b c
g
d e
ENP-740 REV A 8/5/2020 (Printed and downloaded copies are uncontrolled) 57 of 90
13 1. Verify clearance
between PRD vent
tubes (a) and live high
pressure PRD vent tubes
(b) is 3/8-in. minimum.
2. Verify clearance
between all system
plumbing and cylinders (c)
is 3/8-in. minimum.
If required: Adjust
clamps as necessary and
repeat Step 13.
WHY WHAT
Prevent fuel line damage.
b
a b
c
NOTE: Plug end shown for 120-in. cylinder pod
reference; valve end similar.
ENP-740 REV A 8/5/2020 (Printed and downloaded copies are uncontrolled) 58 of 90
14 1. Install ferrules (not
visible) and nut (a) from
tee fitting (12), p/n
10200208, on PRD vent
tube (13), p/n 25519416.
2. Install ferrules (not
visible) and nut (b) from
tube fitting (14), p/n
10200065, on straight
end of PRD vent tube
(13).
3. Install ferrules (not
visible) and nut (c) from
tee fitting (12), p/n
10200208, on tube
adapter fitting, (17), p/n
10200238.
Refer to Appendix A:
WI.0197 Manual Swaging
of Swagelok Fittings.
4. Install tee fitting (12), p/n
10200208, on PRD vent
tube, (13), p/n
25519416.
Tighten fitting finger
tight; fitting will be
tightened at a later step.
WHY WHAT
b
13
12
14
a
12
17
c
120-in. cylinder pod
ENP-740 REV A 8/5/2020 (Printed and downloaded copies are uncontrolled) 59 of 90
15 1. Install two tube clamp
kits (15), p/n 10701508,
from retrofit kit on PRD
tube, (13), p/n
25519417.
2. Insert one 1.5-in. hex
cap screw (a), p/n
10760200-0150, and
one 2.5-in. hex cap
screw (b), p/n
10760200-0120, into
each tube clamp kit
(15), as shown in INSET
A.
3. Install one flat washer,
p/n 10761000, and one
flange top nut, p/n
10763000 (not shown)
on each hex cap screw
inserted in previous sub
step.
4. Secure PRD vent tube
(13) to PRD bracket (9)
at existing holes
(circled).
To ease component
installation, do not
tighten fasteners
completely; fasteners
will be torqued at a later
step.
WHY WHAT
Support PRD vent lines.
15
13
9
120-in. cylinder pod
ENP-740 REV A 8/5/2020 (Printed and downloaded copies are uncontrolled) 60 of 90
16 Install PRD vent supply
tube (5d) on tee fitting (12)
at nut fitting (a).
Tighten fitting (a) finger
tight; fitting will be
tightened at a later step.
WHY WHAT
12
5d
120-in. cylinder pod
a
ENP-740 REV A 8/5/2020 (Printed and downloaded copies are uncontrolled) 61 of 90
17
Always use a
backing wrench on the
main fitting while using a
wrench to install another
fitting.
1. Install tube adapter
fitting (17), p/n
10200238 on VTI PRD
(16b), p/n 10300513.
Torque fitting (17)
to 26 ft-lbs
(35.25Nm)
2. Install straight fitting
(18), p/n 10200563, on
VTI PRD (16a), p/n
10300513.
3. Install straight fitting
(18), p/n 10200563, on
VTI PRD (16a), p/n
10300513.
Torque fittings (18)
to 18.5 ft-lbs
(25Nm).
4. Install tube fitting (14),
p/n 10200065, on VTI
PRD (16a), p/n
10300513.
Torque fitting (14)
to 45 ft-lbs (61Nm).
WHY WHAT
16a
14 17
18 16b 18
120-in. cylinder pod
ENP-740 REV A 8/5/2020 (Printed and downloaded copies are uncontrolled) 62 of 90
18 1. Install VTI PRD (16a)
assembly inlet fitting (a)
on PRD supply tube
(13) at tee fitting (12).
2. Install VTI PRD (16b)
outlet fitting (b) on
straight end of PRD
supply tube (13) nut
fitting.
Tighten fittings finger
tight; fittings will be
torqued at a later step.
WHY WHAT
b 13 12 a
16b 16a
120-in. cylinder pod
ENP-740 REV A 8/5/2020 (Printed and downloaded copies are uncontrolled) 63 of 90
19 1. Install PRD vent tube
(29), p/n 25519027, on
VTI PRD (16b) fitting
(a).
Tighten nut fitting finger
tight; fittings will be
tightened at a later step.
2. Slip two dual tube
clamps (8) on PRD vent
tube (29), and on PRD
supply tube (5d).
3. Use dual tube clamp (8)
fasteners (not visible) to
secure two clamps (8)
and two plates (6), to
PRD bracket (9) at hole
(circled).
4. Slide P-clip (7) on PRD
vent tube (29) and use
existing fastener to
secure P-clip (7) to Pclip
bracket (b).
Tighten fasteners finger
tight; fasteners will be
torqued at a later step.
WHY WHAT
5d
16b a 8 6 29
7
b
120-in. cylinder pod
ENP-740 REV A 8/5/2020 (Printed and downloaded copies are uncontrolled) 64 of 90
20 1. Install nut fitting (b) of
PRD vent tube (38) on
VTI PRD (16a) outlet
fitting (a).
Tighten fitting finger
tight; fitting will be
tightened at a later step.
2. Install tube clamp kit
(15), p/n 10701508, on
PRD vent tube (38).
3. Use tube clamp kit (15)
fasteners (not visible)
from to secure clamp to
PRD bracket (9).
Tighten fasteners finger
tight; fasteners will be
tightened at a later step.
WHY WHAT
15 16a
9
38
120-in. cylinder pod
b a
ENP-740 REV A 8/5/2020 (Printed and downloaded copies are uncontrolled) 65 of 90
21 A. Use two
wrenches to tighten
1/2-in. Swagelok® nut
fittings at four locations in
the following sequence:
1. (a)
2. (b)
3. (c)
4. (d)
Tighten 1/2-in.
Swagelok® nut fittings
per Appendix B WI.0441.
B. Verify vent ports (f)
of VTI PRDs (16a)
and (16b) are pointing
down (arrows).
WHY WHAT
System specification.
120-in. cylinder pod
16a b a
d
16b
f
f
c
ENP-740 REV A 8/5/2020 (Printed and downloaded copies are uncontrolled) 66 of 90
22 Use two wrenches to
tighten SAE / JIC
fittings at two locations
(circled) in the following
sequence:
1. (a)
2. (b)
Tighten SAE / JIC fittings
to 45 ft-lbs (61Nm).
WHY WHAT
System specification.
120-in. cylinder pod
a b
ENP-740 REV A 8/5/2020 (Printed and downloaded copies are uncontrolled) 67 of 90
23 1. Install tube clamp
bracket (23), p/n
25519123, on existing
double tube clamp (7)
using double tube clamp
fasteners (not shown).
2. Slip P-clip (8), p/n
10702147, on PRD vent
tube (38), p/n 25519038.
3. Install P-clip (8) on tube
clamp bracket (23), p/n
25519123 using one
hex cap screw, p/n
10760200-0100, one flat
washer, p/n 10761000,
and one flange top nut,
p/n 10761300.
Tighten fasteners finger
tight; fasteners will be
tightened at a later step.
WHY WHAT
System specification.
120-in. cylinder pod
8
23
38
7
ENP-740 REV A 8/5/2020 (Printed and downloaded copies are uncontrolled) 68 of 90
24 Tighten clamp
fasteners at all clip
and clamp locations
(circled) using the following
sequence:
1. (a)
2. (b)
3. (c)
4. (d)
5. (e)
6. (f)
7. (g)
Tighten fasteners to 8 ftlbs
(11Nm).
WHY WHAT
System specification.
Proper tightening
sequence is crucial to
fuel system integrity.
120-in. cylinder pod
f
c b a
g
e
d
ENP-740 REV A 8/5/2020 (Printed and downloaded copies are uncontrolled) 69 of 90
25 1. Verify clearance
between PRD vent
tubes (a) and live high
pressure PRD supply
tubes (b) is 3/8-in.
minimum.
2. Verify clearance
between all system
plumbing and cylinders (c)
is 3/8-in. minimum.
If required: Adjust
clamps as required and
repeat Step 25.
WHY WHAT
Prevent fuel line and
cylinder damage.
b
a
c
120-in. cylinder pod
NOTE: Plug end shown for
reference; valve end similar.
ENP-740 REV A 8/5/2020 (Printed and downloaded copies are uncontrolled) 70 of 90
26 Apply quantity four
Decal, System,
Danger Live High Pressure
PRD Line (a), p/n
10602157, to PRD supply
tubes as indicated.
WHY WHAT
Operator and first
responder safety.
27 Apply quantity four
Decal, PRD Vent Line,
Caution (b), p/n 10602442,
to midpoint of PRD vent
tubes as indicated.
WHY WHAT
Operator and first
responder safety.
a
a a
120-in. cylinder pod
b
b
b
b
b
120-in. cylinder pod
ENP-740 REV A 8/5/2020 (Printed and downloaded copies are uncontrolled) 71 of 90
5.6. Check PRD vent tube outlet clearance
1 1. Gently close one
fuel system roof
pod door.
2. Visually verify proper
clearance between plug
end PRD vent tube cap
(f) and door opening
(circled).
3. Visually verify proper
clearance between
valve end PRD vent
tube caps (f) and door
opening (circled).
PRD vent tubes cannot
protrude above the top of
the pod door.
If PRD vent tube caps
protrude above the pod
door opening, fuel system
plumbing must be adjusted
to achieve proper
clearance.
Verify all PRD vent tube
caps are installed.
2 Repeat Step 1 for each roof
pod door.
WHAT
WHAT
WHY
Verify proper PRD vent
tube position.
WHY
Verify proper PRD vent tube
position.
12
5a
f f 15
9
f
f
ENP-740 REV A 8/5/2020 (Printed and downloaded copies are uncontrolled) 72 of 90
5.7. System Leak Check Procedure
1 1. Turn 1/4-turn manual shut
off valve (3) on the FMM (2)
to the OPEN position.
2. Select the appropriate CNG
fuel nozzle and/or adaptor
for the FMM (2) fuel fill
receptacle (not visible).
3. Remove fuel fill receptacle
dust cap (f).
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.
2
f
3
ENP-740 REV A 8/5/2020 (Printed and downloaded copies are uncontrolled) 73 of 90
2 Monitor FMM (2) high
pressure gauge (b) 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.
2 b
ENP-740 REV A 8/5/2020 (Printed and downloaded copies are uncontrolled) 74 of 90
4 1. Begin at one end the
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 Agility® publication
ENP-729 to defuel system.
WHAT
WHAT
WHY
WHY
6 Re-tighten leaking
fitting(s) discovered
during Step 5.
1. For JIC fittings,
refer to p/n specific
tightening
instructions.
2. For compression
fittings, tighten
fitting according to
Appendix B.
7 Repeat Steps 1 and 2 to
repressurize the system.
WHAT
WHAT
WHY
WHY
ENP-740 REV A 8/5/2020 (Printed and downloaded copies are uncontrolled) 75 of 90
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.
Follow fitting
installation directions
in Appendix 2.
13 Repressurize fuel system by
repeating Step 1 and Step 2.
WHAT
WHAT
WHY
WHY
ENP-740 REV A 8/5/2020 (Printed and downloaded copies are uncontrolled) 76 of 90
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 the 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) fuel fill
receptacle (a).
19 Replace dust cap (f) on FMM
(2) fuel fill receptacle (a).
WHAT
WHAT
WHY
WHY
Vehicle will not start if dust
cap is not in place.
2
a
2
f
ENP-740 REV A 8/5/2020 (Printed and downloaded copies are uncontrolled) 77 of 90
20 If not open, turn FMM
(2) 1/4-turn manual shut
off valve (3)
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.0323 (c) to record
the result and the date
on which the fuel system
passed the 3600 psi
test.
23
Apply Torque Seal (a) to all
fitting junctions (b).
WHAT
WHY
Verify safe and proper
fuel system pressure
specification.
System quality specification.
3
2
c
b
a
ENP-740 REV A 8/5/2020 (Printed and downloaded copies are uncontrolled) 78 of 90
5.8. Reporting and Return Procedure
1 1. Use form FT.0323
(c) to record the
following data for each
VTI™ replacement PRD
(16):
C. Serial number (a)
D. Location of each VTI™
PRD (circled), within the
fuel system.
2. Inspect fuel system
repairs per the quality
assurance criteria
specified in FT.0323.
Use a flashlight to aid data
identification and inspection
in low light.
3. Use a camera or
camera phone to take a
photo of completed form
FT.0323 (c).
4. Submit photo of
completed form FT.0323
(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
16
a
ENP-740 REV A 8/5/2020 (Printed and downloaded copies are uncontrolled) 79 of 90
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.
ENP-740 REV A 8/5/2020 (Printed and downloaded copies are uncontrolled) 80 of 90
Appendix A. WI.0197 Manual Swaging of Swagelok Fittings
ENP-740 REV A 8/5/2020 (Printed and downloaded copies are uncontrolled) 81 of 90
ENP-740 REV A 8/5/2020 (Printed and downloaded copies are uncontrolled) 82 of 90
ENP-740 REV A 8/5/2020 (Printed and downloaded copies are uncontrolled) 83 of 90
ENP-740 REV A 8/5/2020 (Printed and downloaded copies are uncontrolled) 84 of 90
Appendix B. WI.0441 Tightening of tube fittings
ENP-740 REV A 8/5/2020 (Printed and downloaded copies are uncontrolled) 85 of 90
ENP-740 REV A 8/5/2020 (Printed and downloaded copies are uncontrolled) 86 of 90
Appendix A. Emer™ Instruction Manual to Replace the PRD
MOD 8.7-03 Rev01
INSTRUCTION MANUAL TO REPLACE THE PRD
GENERAL INSTRUCTIONS
Read carefully the instructions before proceeding with the replacement of the Pressure
Relief Device (PRD) Temperature Activated. The maintenance described hereinafter shall
be done only by the authorized workshops/operators after Emer S.p.A. approval.
Don’t damage or tamper in any way the valve and its equipment.
Don’t use components having damaged packaging, fallen or showing sign of collision
and/or damages.
Don’t make operations different from those explicitly described in this instruction
manual.
All the equipment used for the hereinafter listed operations, shall be suitable to the
using and calibrated (where applicable).
For what not expressly described, the indication reported within the standard ISO 19078
“Gas cylinders — Inspection of the cylinder installation, and requalification of high
pressure cylinders for the on-board storage of natural gas as a fuel for automotive
vehicles” and the following have to be used.
Before conducting following activities it is mandatory that inside the
CNG tank and the downstream systems there isn’t any residual pressure. This
means that the tank, the piping, etc. should be completely vented.
Pay attention not to damage the components during the following activities.
Emer S.p.A. – a Westport Fuel Systems company
Via Bormioli 19 • 25135 • Brescia • Italy – Tel +39 030 2510391 • Fax +39 030 2510392 • emer.westport.com
ENP-740 REV A 8/5/2020 (Printed and downloaded copies are uncontrolled) 87 of 90
1. Unpack the fresh PRD keeping the plastic bag, the protective plastic cap and the
main carton box.
2. Unscrew the PRD Part 2 at Fig 1.
3. Remove the previous O-ring from the seat at the valve body, blow compressed air
into the seat of the PRD and check that the fresh PRD is having the O-ring at the
proper seat.
4. Apply the sealant as specified at Table 1 on the threads of the new PRD and screw
the PRD into the threaded seat at the valve body.
5. Tighten the PRD with a dynamometric key size 24 set at a torqueing value as declared
in Table 1.
6. Pressurize the system at min 200 bar with CNG. The pressurizing of the CNG can be
done either with a back-up CNG tank or at the CNG filling station. Do not use CNG
fast filling stations for pressurizing the systems. In case of multiple tanks all the
tanks must be pressurized (all the PRDs present in the system should be replaced
before conducting the leak test at Step No 7).
7. Check the tightness of the PRD at the sealing area of the valve using either sniffer
measuring machine (preferably) or with snoop solution (in case sniffer machine is
not available). With snoop solution the PRD is leak proof in case of no bubbles. If
sniffer machine is used please contact Emer at emer-service@wfsinc.com specifying
the technical details of machine for defyning acceptance criteria.
ENP-740 REV A 8/5/2020 (Printed and downloaded copies are uncontrolled) 88 of 90
Fig 1
2
2
2
ENP-740 REV A 8/5/2020 (Printed and downloaded copies are uncontrolled) 89 of 90
S. No Tank Valve Part No PRD Type PRD thread
Torqueing
value
Glue
1 MARK106-006 PRD100OR M16x1 30±15% Nm Loctite 276 – 4 mg
2 MARK114 PRD2002T M16x1 30±15% Nm Loctite 276 – 4 mg
3 MARK121-004 PRD200OR M16x1 30±15% Nm Loctite 276 – 4 mg
4 MARK131-003 PRD200OR M16x1 30±15% Nm Loctite 276 – 4 mg
5 MARK137-001 PRD200OR M16x1 30±15% Nm Loctite 276 – 4 mg
6 MARK139 PRD200OR M16x1 30±15% Nm Loctite 276 – 4 mg
7 MARK147-005 PRD200OR M16x1 30±15% Nm Loctite 276 – 4 mg
8 MARK147-008 PRD2102T M16x1 60±10 Nm Loctite 276 – 4 mg
9 MARK155-001 PRD210ORMP M16x1 30±15% Nm Loctite 276 – 4 mg
10 MARK156-003 PRD2102T M16x1 60±10 Nm Loctite 276 – 4 mg
11 MARK156-006 PRD2102T M16x1 30±15% Nm Loctite 276 – 4 mg
12 MARK160 PRD100OR M16x1 30±15% Nm Loctite 276 – 4 mg
13 MARK163-003 PRD200OR M16x1 30±15% Nm Loctite 276 – 4 mg
14 MARK169 PRD210OR M16x1 30±15% Nm Loctite 276 – 4 mg
15 MARK193 PRD200OR M16x1 30±15% Nm Loctite 276 – 4 mg
16 MARK199-003 PRD210OR M16x1 30±15% Nm Loctite 276 – 4 mg
17 MARK199-004 PRD210OR M16x1 30±15% Nm Loctite 276 – 4 mg
18 MARK199-006 PRD2102T M16x1 30±15% Nm Loctite 276 – 4 mg
19 MARK703-002 PRD217OR M16x1 30±15% Nm Loctite 276 – 4 mg
Table 1
Emer S.p.A. declines any responsibility for eventual damages due to person, things or
animals directly and indirectly, as a consequence of non-observation of instructions and
assembly, use and maintenance directions of the component.
For every controversy concerning the execution and/or interpretation of the present
contract, it is applicable the Italian Law and the place of jurisdiction is Brescia’s court of
justice.
In case of any assistance, contact Emer S.p.A. at emer-service@wfsinc.com
ENP-740 REV A 8/5/2020 (Printed and downloaded copies are uncontrolled) 90 of 90
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® Customer Care:
+1 949 267 7745
+1 855 500 2445 toll free
parts@agilityfs.com
Proprietary Statement
The information provided within this document is proprietary and confidential. All prior
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
customers and clients. No portion of this publication may be reproduced or distributed without
express written consent of Agility®. Agility® reserves the right to utilize the intellectual property
contained within this publication as content for any other publication produced by Agility®.
Trademark Notice
Agility® is a trademark of Agility Fuel Solutions LLC. Trademarks of other manufacturers are
the property of their respective companies.
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 06/11/2020
A
ADDED: Instruction to
capture solenoid valve
serial number and batch
number data for each valve
PRD removed
C.Grasso CCG Team 8/5/2020