ENP-741 – Emer™ PRD Replacement for Gillig CNG Fuel Systems with Type 3 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.
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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 4.
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 Cylinder Plug 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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5.4.1. 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 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
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2
Use form FT.0321 (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
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5.4.2. Remove and replace Emer™ Cylinder Valve PRDs
Refer to Appendix A: “OEM Emer Instruction PRD Manual to Replace the PRD” (below) for installation details.
1 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).
If necessary: 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.
WHY WHAT
6 1
7
d
8
e
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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
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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
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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
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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
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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 If loosened at Step 1 above:
Use a wrench to tighten dual
tube clamp (8) fasteners (not
visible).
Torque tube clamp (8)
fasteners to 8 ft-lbs (11Nm).
WHAT
WHAT
WHY
System specification.
WHY
System specification.
10 Repeat Steps 1 through 9
until all eight valve end
PRDs have been replaced.
WHAT
WHY
6
a
7
8
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5.5. 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 caps
(f) and door opening
(circled).
PRD vent tubes cannot
protrude above the top of
the pod door.
If PRD vent tube (2) caps
(f) protrude above the pod
door opening, fuel system
plumbing and/or mounting
clamps (b) must be
adjusted to achieve proper
clearance.
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.
5a
f f
f
2
b
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5.6. 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.0321 (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 cylinder plug
PRDs (3) replaced.
25
Use a blue paint marker to
mark a stripe (a) on all eight
cylinder valve PRDs (4)
replaced and on the valve
body (5).
WHAT
WHY
Easily identify replaced
cylinder plug PRDs.
Easily identify replaced
cylinder valve PRDs.
3
a
4
a
5
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5.7. Reporting and Return Procedure
1a 1. Use form FT.0321
(c) to record the
Date of Manufacture (a)
and batch number (b)
and the location of each
replacement plug PRD
(16), p/n 10301046,
within the fuel system.
2. Inspect fuel system
repairs per the quality
assurance criteria
specified in FT.0321.
Use a flashlight to aid
serial number identification
in low light.
3. Use a camera/phone to
photograph completed
form FT.0321 (c).
4. Submit photo of
completed form FT.0321
(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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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
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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 [email protected] specifying
the technical details of machine for defyning acceptance criteria.
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Fig 1
2
2
2
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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 [email protected]
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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
+1 855 500 2445 toll free
[email protected]
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 registered 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 06/02/2020
A
DELETED: Instructions
to return PRDs to
Emer™ from Appendix A.
C. Grasso CCG Team 06/05/2020
B
ADDED: Instruction to
capture solenoid valve
serial number and batch
number data for each
valve PRD removed.
C.Grasso CCG Team 08/05/2020