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OPERATION AND MAINTENANCE
MANUAL
FOR
TATA MARCOPOLO
HIGH PRESSURE CNG SYSTEM & COMPONENTS
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INDEX
S.NO DESCRIPTION PAGE NO.
1 CNG System and components 3
2 Safety standards used in CNG system 4
3 Do's and Don’ts of CNG system 4
4 Circuit diagram of CNG system 5
5 Beta new cylinder valve 6
6 TN 5 Receptacle 14
7 H.P Filter 21
8 Pressure Gauge 30
9 Apus Solenoid valve 36
10 Check valve 42
11 Transducer 46
12 Spare Part List 50
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Compressed Natural Gas (CNG)
Compressed Natural Gas is a clean and economical alternate fuel for vehicles. There aremore than 6,119,409 Natural Gas Vehicles running all over the world. CNG is made up
of 90% methane and the rest is propane, butane and other constituents. Natural Gas
Vehicles are considered to be the cleanest transportation modes in the world. This isbecause with better technologies in natural gas engines the levels of pollutants like NOx,particulate matter, carbon monoxide etc. has been greatly reduced compared to traditional
diesel or petrol engines. It has a higher octane number than petrol. Natural gas occupies ahigher volume than liquid fuels and therefore has to be compressed and stored on
vehicles to get maximum range from vehicles. In India the maximum pressure to whichnatural gas is compressed is 200 bars and is stored in steel cylinders on vehicles. CNG is
dispensed at filling stations in kilograms. CNG is a very safe fuel, however can ignite andexplode if it comes into contact with a flame or ignition source.
The parameters of a CNG system are given below• Vibration Resistance
• Pressure Temperature variation (-40C to 85C).• Corrosion Resistance.• Pressure Holding Capacity.
• Cycle Life.• Compatibility.
Component Groups within a CNG fuel system
As natural gas is compressed and stored in cylinders on a vehicle at 200 bar there arecomponents in a typical CNG system that are different from a traditional fuel system.
Due to the high pressure in the system safety precautions are taken to ensure maximum
safety of the vehicle passengers and also to ensure a smooth uninterrupted supply of gasto the engine. The major components of the CNG fuel system on the vehicle are:
· Refueling receptacle
· Pressure gauge
· Cylinder Valve
· Particulate and coalescing filter
· Transducer and dash board indicator
· Stainless steel tube and two-ferrule fittings
· Pressure Regulator
· Check Valve
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Safety Standards used for CNG System
• ECE R110 – Is European regulation. No component in Europe can be used on
CNG vehicle without conforming to this regulation.
• ISO 15500- Is divided into 19 parts and each part covers specific tests for type of component. Compliance is not mandatory.
• ANSI/NGV 3.1 – Is standard of North America and compliance for components is
mandatory.
All standard address safety of components for High pressure systems.
CNG System – Do’s
• Always Inspect joints etc. under pressure for leaks and proper installation after re-
installation.
• Ensure tubing is bottomed on Fitting body before re-tightening.
• Always bleed gas from lines before servicing any CNG components.
• Ensure that meting components threads are of same standards.
• Tighten all the connectors as per the instruction of fitting manufacturer.
• Always check cylinder and cylinder valve alignment.
CNG System- Don’ts
• Never loosen any Component when system is pressurized.
• Do not tighten taper threads without Teflon tape.
• Do not over-tighten drain plug of filter after draining.
• Do not put excessive weight or lean on tubing.
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CIRCUIT DIAGRAM
NOTE:GREENFUEL SCOPE OF SUPPLY:
1. Cylinder valve
2. Solenoid valve3. Check valve4. Pressure gauge5. Receptacle6. Filter7. Transducer
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BETA NEW CYLINDER VALVE
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GENERAL DESCRIPTION
Beta new valve is a manual cylinder valve provided at the mouth of a gas cylinder. The
main function of this valve is to shut off gas flow from the cylinder in to the system
during maintenance.In addition, Beta new valve comes with 3 inbuilt safeties, namely an excess flow device,a burst disc and a fusible plug. These safety devices provide protection against over
pressure, fire and in case of line rupture.The burst disc and the fusible plug are pressure relief devices (P.R.D.) which are inline,
but operate independently.Beta new valve is made up of brass material (Nickel plated).
PICTORIAL VIEW
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CONSTRUCTION
Beta new valve consists of following components.
(1) Excess flow deviceThis is an inbuilt safety device which activates on excessive increase of the flow rate of gas.
(2) Burst Disc
This is a pressure relief device which activates in case of excessive increase of gaspressure in the tank.
(3) Fusible plug
Fusible plug is also a pressure relief device which is a thermal safety activated in case of excessive increase of a temperature in a zone near the valve.
(4) Manual tap
On the top of beta new valve, a hand wheel is provided for the opening and closing thepath of the gas. This tap or hand wheel is normally open but it will be closed at the time
of maintenance.
OPERATION
On top of every hand wheel of the valve the opening and closing directions are clearly
marked for the operator to have a visual indication of the direction for opening andclosing. In addition there are also the letters “O” marked for opening and “C” for closing.
To open the valve the hand-wheel must be turned in the anti-clockwise direction.
To close the valve the hand-wheel must be turned in the clockwise direction.
NOTE: While opening and closing the valve, do not try to over turn the valveknob from its stop position.
Cylinder Valve hand wheel
with open and close positions
marked
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TECHNICAL DATA SHEET
Description Value
Pressure Maximum working pressure 260 BarTest pressure 275 Bar
Hydraulic collapse pressure>800 Bar (withoutburst disc)
Temperature Working Temperature -40 to +85 0CPRD activation temperature 108 ± 6 0C
P.R.D safetydevice Minimum area of gas flow 38,5 mm2
Empty tank time 104 sec.(Volume=100 liters/ Pressure=220 barP.R.D activation time 10 sec.(Fire directed on P.R.D)
Burst disc Minimum area of gas flow 12,6 mm2
Burst pressure (at roomtemperature) 300 bar+10%
Manual valve Minimum area of gas flow 28,3 mm2
Manual tap Tightening torque at 360 bar 4 ± 1 N-mopening/closing angle 3600 ± 900
Excess flowPressure difference valveactivation 6,5 Bar
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INSTALLATION OF BETA NEW VALVE
Storage
Beta new valve should be stored in a covered area. If covered area is not available, anywater proof covering material should be provided over the valve. The valve should be
kept on a wooden pallet at least 150 mm above the ground level.Do not apply tar, paint, grease or any other material inside the valve as this could impair
performance of the valve.
Installation procedure
The procedure for the installation of Beta new cylinder valve with 1” BS 341 cylinderthread when tightening it on a steel CNG cylinder are given below.
a) Remove the thread protection caps.
b) Verify that valve cylinder threads are clean.
c) Check that the threads on the neck of the cylinder are perfectly shaped and freefrom irregular burrs or edges.
d) Use a suitable Teflon tape (minimum density of 1.2 g/cc); start wrapping the tapeon the cylinder valve thread in the direction of male tapered thread spiral, and join
with a slight overlap.
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e) Make sure that tape does not overhang the first thread.
f) Cut off excess tape and draw free end of the tape and press firmly at the overlay
point.
g) Check that the threads on the neck of the cylinder are perfectly shaped and freefrom irregular burrs or edges.
h) Manually insert the valve thread into the cylinder neck and screw manually till the
threads do not engage further.
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i) Using a torque wrench and correct tool fixture for the cylinder valve. Tighten thevalve to a torque value between 200-300 Nm.
j) Does not hold the valve (as shown in below picture) while tightening on the
cylinder neck? It may damage the fusible plug or manual tap.
START-UP
After complete installation of the cylinder valve, check all the connections and then
slowly open the hand wheel/tap of the valve until it is fully open.
Tightening tool of
beta new valve
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TOOLS AND SPARE PARTS DATA SHEET
S.NOTOOLS AND SPAREPARTS REQUIRED
GREENFUELPART NO. PREACAUTION
1Torque wrench andTightening tool GF-200-TT-B
Tighten the valveto a torque valuebetween 200-300Nm.
2 Teflon TapeGF-S-STR-4
Make sure thattape does notoverhang the firstthread.
TROUBLE SHOOTING DATA SHEET
S.NO PROBLEM CAUSE SOLUTION
1
Leakage throughcylinder threads Over tightening
In case of overtightening, the valvethreads will be damaged.
Change the valve with anew one and install it asper the instructions.
Teflon tape is notproperly wrapped
Unwrapped the Teflontape and again wrap anew Teflon tape as perinstructions (d), (e) and(f).
2
In case ofactivation of PRD
devices
Due to highpressure or
temperature.
Change the cylindervalve and do not attemptto re-use the same
valve.
3
If gas is not comingfrom the cylinder
Excess flow deviceis activatedbecause of
pressure difference
1. Close the cylindervalve and wait for15-20 mins.
2. Slowly open thecylinder valve.
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TN5 FILLING RECEPTACLE
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GENERAL DESCRIPTION
TN-5 Receptacle is a filling receptacle for Trucks and Buses. The main function of a
filling receptacle on a natural gas vehicle is the device through which gas is filled in thevehicle. The filling receptacle gets “locked in” with the filling nozzle at the filling stationand gas flow into the vehicle starts. TN-5 filling receptacle is a NGV profile and is used
for fast fill operations.TN-5 receptacle serves the following very important functions on a Natural Gas Vehicle:
· Allows for fast flow of gas into vehicle.
· Has check valve in-built to ensure there is no back flow of gas.This receptacle is made up of Stainless steel (S.S) body. During fast filling of gas in thevehicle it does not make any chatter or noise.
PICTORIAL VIEW
Panel mount nut
O-ring
.
Two-Ferrule end
connection
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CONSTRUCTION
(1) Check valve
In a TN-5 receptacle, an inbuilt check valve is provided. This inbuilt check valve ensuresthere is no back flow of gas.
(2) O-ring
The o-ring within the receptacle should be specially designed to withstand the harshenvironment of a natural gas vehicle. The o-ring should not be in the direct path of the
gas and preferably should be enclosed within a groove so that there is no direct abrasionand it has a longer service life.
TECHNICAL DATA SHEET
Description Value
Pressure Nominal pressure (PN) 200 BarService pressure (PS) 260 BarTest pressure (PT) 390 Bar
Temperature Working Temperature -40 0C up to +120 0C
Design Nominal Diameter (DN) 12 mm
INSTALLATION
Storage
A TN-5 filling receptacle should be stored in a covered area. If covered area is not
available, any water proof covering material should be provided over the receptacle. Thereceptacle should be kept on a wooden pallet at least 150 mm above the ground level.
Do not apply tar, paint, grease or any other material inside the valve as this could impairperformance of the receptacle.
Installation procedure
(a) Remove the receptacle from the box.
(b) Unscrew the ½” OD nut and remove it for panel mounting. Take care to ensurethat the nut and ferrules remain undamaged.
(c) Unscrew the panel mounting nut provided on the receptacle.
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(d) Keeping the NGV profile in the front insert the receptacle into the panel holeprovided as per drawing.
(e) Screw the panel mounting nut back on the receptacle from the back of the panel.
(f) Tighten the panel mounting nut to a torque of 40Nm.
(g) Screw the Nut with ferrules back onto the fitting body machined on the receptacle.
(h) Caution! Care should be taken to ensure that the nut and ferrules are properly
oriented in position.
(i) Insert tube into OD end connection and tighten as per standard instructions of tightening two ferrule fittings.
START-UP
After complete installation of TN5 filling receptacle, check all the connections with thehelp of gap inspection gauge. Always check that the filling nozzle which will be lockedin with receptacle are NGV type.
Maintenance ProcedureAlthough the filling receptacle does not require any periodic maintenance it is goodpractice to replace the o-rings within a receptacle after every 4 years or 300,000 Kms.
Keeping Indian gas conditions in mind this is a safe period for replacement to ensureproper functioning of the receptacle.
Change the O-ring like the pictures which are given below:
(1)
(2)
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TOOLS AND SPARE PARTS DATA SHEET
S.NO. DESCRIPTION PART NO. PRECAUTION
1 O-ringGF-50-E-159S568
Always use the WEH makeoriginal O-ring for the
receptacle
TROUBLE SHOOTING DATA SHEET
S.NO PROBLEM CAUSE SOLUTION
1Leakage from the end
connection
Two ferrule endconnection is notproperly installed
Again tighten the ferrulefitting as per the standardinstruction for two ferrulefitting.
2O-ring found damage
conditionDirt particles in gas ornozzle are old.
Change the O-ring as perthe maintenance procedure.
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H.P FILTER
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GENERAL DESCRIPTION
A high pressure Particulate and coalescing filter is provided on the vehicle just prior to
the High pressure regulator. This filter is capable of filtering out the dirt particles as wellas the oil and aerosol droplets from the gas. The main reason for this filter is to safe guard
the High pressure CNG regulator and all the rest of the downstream components. Thisgives a longer working life to all the components and also ensures that there is no damage
to the important functional components. In addition to filtering out the dust that can causeabrasion damage to the seats and seals of valves, the filter ensures that oil and aerosol
particles don’t cause waxing of the regulator or blockage in low pressure systems.The main features of TSF2 Filter are given below.
· Integrated fine filter efficiency of 95% at 0.1 micron.
· Light aluminum construction.
· High-grade CNG particle filter.
· Different flow directions possible.
PICTORIAL VIEW
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CONSTRUCTION
(1) Drain Plug
The natural gas flows through the filter, whereas the parts like oil and other liquidaerosols generate drops, which drop to the sump of the filter, these drops are drain by the
opening of drain plug.
(2) O-ringThe o-ring within the drain plug of a filter should be specially designed to withstand the
harsh environment of a natural gas vehicle. The O-ring of a drain plug is given below inthe picture.
O-Ring
(3) Filter Element
Filter element is used to filter the gas and remove the parts like oil, water aerosols and
dirt particles. The picture of an element is given below.
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(4) Screw Plug
It is to be open and closed at the time of filter element replacement that is after every
54000 Kms. The screw plug is tightened in the filter with a torque of 100 Nm.
(4) Stay Bolt
It is used to hold the filter element between inside the filter. The stay bolt is tightened inthe filter with a torque of 11-14 Nm.
TECHNICAL DATA SHEET
Description Value
Pressure Nominal pressure (PN) 200 BarService pressure (PS) 260 Bar
Test pressure (PT) 390 Bar
Temperature Working Temperature -40 0C up to +120 0C
Flow rate (KV) 0.34
INSTALLATION
Storage
A TSF2 Filter should be stored in a covered area. If covered area is not available, any
water proof covering material should be provided over the filter. The filter should be kepton a wooden pallet at least 150 mm above the ground level.Do not apply tar, paint, grease or any other material inside the filter as this could impair
performance of the filter.
Installation procedure
a. Remove the Filter from the box and plastic caps.
b. Prepare male connectors properly and tighten them on the inlet and outlet of filter.
c. On the top of the filter there are arrow markings which indicate the direction of flow of gas.
Inlet >>>>>>>>>>>> Outlet
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d. While mounting the filter on the filter bracket care should be taken to mount the
filter in the proper orientation with regard to the flow of gas.
e. The filter has 4 holes of M6 threads on top and 4 M6 bolts along with suitable
washers should be used to tighten the filter on the mounting bracket.
f. The bolts should be tightened to a torque of 11-14 Nm.
g. The bottom of the filter comes equipped with a 9/16-18 UNF drain plug and it is
tightened with a torque of 40 Nm.
h. Insert tubes into male connecters and tighten as per standard procedures.
i. CAUTION: While installing the filter do not try to open or tight the drain plug of the filter.
START-UP
After complete installation of the high pressure filter, check all the connections with thehelp of gap inspection gauge. Check that filter is mounted properly and drain plug is
present in the filter.
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MAINTENANCE PROCEDURE
The filter requires periodic maintenance to ensure that the filter is cleaned and theelement used in it is working properly. Before starting maintenance, ensure that all the
gas in the downstream system has been completely vented and the cylinder valves should
also be closed, prior to opening the drain plug.
1. Maintenance Procedure for Draining of oil
Ø Draining of oil is required after every 9000 Kms.
Ø Open the drain plug with the help of spanner and allow draining the oil.Ø CAUTION: While opening and closing of drain plug, always hold the
screw plug with spanner.Ø After draining of oil, clean the surface with a clean cotton cloth.
Ø After draining of oil, re-tighten the drain plug with the torque of 40 N-m.Ø CAUTION: Always change the o-ring of drain plug before re-tighten it
into the filter.Ø After tightening of drain plug always check the torque of screw plug that
is 100 N-m.
2. Maintenance Procedure for filter element replacement
.Ø Filter element replacement is required after every 54000 Kms.
Ø Open the filter from the bus and fix it on bench wise.Ø Unscrew the screw plug the proper tool as shown in the below picture.
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Ø Unscrew the stay bolt and fall out the filter element as shown in the belowpictures.
Ø Remove all accessories from the screw plug and filter. Clean the screwplug as shown in the below pictures.
Ø Place a circlip onto the screw plug with the position shown in the below
picture.
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Ø Place back-up o-ring and o-ring of the screw plug as shown in the belowphotographs:
Ø Check the position of all accessories of screw plug as shown on the below
photograph.
Ø Insert the new filter element and tight the stay bolt as shown in the below
photographs.
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Ø Grease the threads of screw plug and tight the screw plug with the torque
of 100 N-m. Make sure that the o-ring, back-up ring and circlip will not bein contact with the depac grease.
3. Maintenance Procedure for Drain Plug Replacement
Ø Drain plug will only be replaced when it will be found in damagecondition.
Ø Change the drain plug with the new one and tighten the new drain plug
with the torque of 40 N-m.Ø Before tightening the drain plug, always checks the condition of drain plug
o-ring.
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TOOLS AND SPARE PARTS DATA SHEET
S.NO
TOOLSAND
SPARE
PARTSREQUIRED
WHEN
REQUIRED TOCHANGE
GREENFUELPART NO. PREACAUTION
1
Drain plug O-
ring
Change after every
draining of oil(every 17000
Kms) GF-50-E-92167
Use Specially
designed and patentedO-ring used for drain
plug.
2 Circlip
At the time of
elementreplacement GF-80-E-93858
Use Specially
designed and patentedcirclip used for drain
plug.
2Screw plugO-ring
At the time of
elementreplacement
GF-50-E-322S568
Use only WEH O-ring.
3
Screw plugBack-up O-
ring
At the time of element
replacement GF-55-E-47144Use only WEH Teflonring
4 Drain Plug In case of damage GF-69-E-9336
Always use a 9/16-18
UNF drain plug.
5 Filter element
After every 54000
Kms. GF-69-E-79770
Use only WEH filter
element.
6
SpecialGrease and
Depac threadlubricant
At the time of
elementreplacement
GF-E99-4
GF-Depac
Don’t use too muchgrease. 1 Bottle of
each is enough for 100vehicles
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TROUBLE SHOOTING DATA SHEET
S.NO PROBLEM CAUSE SOLUTION
1
Leakage from theInlet and outlet
connectionTwo ferrule end
connection is not proper
Screw the end connectionas per the installationinstruction.
2
O-ring of drain plugfound in damage
conditionOver tightening of drainplug.
Replace the O-ring with anew one.
3
If O-ring and Teflonring of screw plugfound in damage
condition
Insufficient lubricant(grease) providedbefore tightening thescrew plug
Change the rings with thenew one and provide thesufficient lubricant (grease).
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PRESSURE GAUGE
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GENERAL DESCRIPTION
Pressure gauge is provided on the vehicle mounted on the panel and is used to indicatethe amount of pressure in the storage cylinders on the vehicle. The pressure gauge
provides visual indication of the amount of gas in the vehicle after filling and also after
the vehicle has run for sometime.The pressure gauge provided on this vehicle is filled with glycerin to ensure that there isdampening of the gauge pointer during vibration and it also prevents damage of the gauge
from moisture present in the gas. The case of the pressure gauge is made up of Stainlesssteel.
PICTORIAL VIEW
(1) Panel Mount pressure gauge
(2) Lower mount pressure gauge
Hex provided for spanner
Glycerin filled pressure gaugeto provide visual indication of
pressure on vehicle.
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TECHNICAL DATA SHEET
Description Value
Pressure Scale ranges up to 0-400 bar
Nominal size Size 63 mm
OperatingTemperature Ambient -20 0C…..+60 0C
Medium +60 0C maximum
INSTALLATION
Storage
A Pressure gauge should be stored in a covered area. If covered area is not available, any
water proof covering material should be provided over the gauge. The gauge should bekept on a wooden pallet at least 150 mm above the ground level.
Do not apply tar, paint, grease or any other material inside the valve as this could impairperformance of the gauge.
Installation procedure
Installation procedure
A pressure gauge is provided into two types of threads that is 1/4" NPT and 1/4" BSP.The installation procedure for 1/4" NPT is given below:
a) Check the threads of the Gauge. There should be no burrs on the threads.
b) Using a high density Teflon tape, Start wrapping the tape on the thread in the
direction of the Male tapered thread and joint with a slight overlap.
Threads of
pressure gauge
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c) CAUTION: – Make sure tape does not overhang the first thread. The tape could
shred and get into the fluid system.
d) Cut-off excess tape and draw free end of the tape and press firmly at the overlay
point.
e) During tightening the gauge spanner should be applied only to the space provided
for the same. (As shown in below picture.) There should not be any force appliedon to the O-Ring of the connector.
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f) CAUTION: Do not try to screw or unscrew by holding it on dial. It should bedone only with the help of spanner.
g) CAUTION: Do not try to open the rubber seal, screws and the rubber o-ring of
the pressure gauge.
The installation procedure for 1/4" BSP is given below:
a. Check the threads of the Gauge. There should be no burrs on the threads.
b. No Teflon tape is required for this type of gauge.
c. During tightening the gauge spanner should be applied only to the space provided
for the same. (As shown in pictorial view.) There should not be any force appliedon to the O-Ring of the connector
d. CAUTION: Do not try to screw or unscrew by holding it on dial. It should be
done only with the help of spanner.
O-ring of gauge
Screws of the gauge
Rubber seal of gauge
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START-UP
After complete installation of the pressure gauge, check all the connections with the help
of gap inspection gauge and always check the level of glycerin.
TROUBLE SHOOTING
S.NO PROBLEM CAUSE SOLUTION
1
Glycerin leakagefrom the pressure
gaugeLeakage when O-ringis damage.
Change the pressuregauge.
Leakage when flangeis loose in panel mountpressure gauge
Change the pressuregauge.
2Pointer not moving
initiallyMovement mechanisminertia
Tap the gauge on the dialslightly 3-4 times.
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APUS SOLENOID VALVE
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GENERAL DESCRIPTION
Apus solenoid valve is an automatic valve provided at the high pressure line of the CNGsystem. The main function of this valve is to shut off the gas flow from cylinder in to the
system, when the ignition of the vehicle is off or in other words it is an on-line cut off
valve.In addition, Apus solenoid valve comes with 12 /24 volts coil both, inlet particle filter of 50 microns, fixing nut, inlet fitting and mounting nut. Solenoid valve is “normally
closed” in functioning and activates only when electric current is passed through thecoils.
Apus solenoid valve is made up of brass material. This solenoid valve is approved by ISO15500, A.R.A.I and E.C.E R110 for an additional safety.
PICTORIAL VIEW
Pressure gauge Hex nut 1.5 Amp super sealed
Mounting connector(Optional)
Fixing Nut
Solenoid Coil
Mounting Nut
Inlet Fitting
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CONSTRUCTION
Apus solenoid valve consists of following components.
(a) Inlet filterAn inlet particle filter is provided with Apus solenoid valve to protect the highpressure line from the external particles which may cause any blockage.
(b) Solenoid coil
Solenoid coil is connected with the ignition of the vehicle. Whenever the current ispassed through the coil, Solenoid valve opens the path for gas to flow into the high
pressure line.
TECHNICAL DATA SHEET
Description Value
PRESSUREMaximum workingpressure 260 bar
Test pressure 330 barHydraulic collapsepressure > 750 bar
TEMPERATURE working temperature -40 to +85 0C
SOLENOIDVALVE
Minimum gas flowingarea 283 mm2
Voltage 12V / 24V DC
Power absorption in allconditions
10W (12V)13W (24V)
opening ΔP between tankand pipes at75% ofnominal power (7.5W) towhich it assures theopening of valve 360 bar
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39
INSTALLATION OF APUS SOLENOID VALVE
Storage
Apus solenoid valve should be stored in a covered area. If covered area is not available,
any water proof covering material should be provided over the valve. The valve shouldbe kept on a wooden pallet at least 150 mm above the ground level.Do not apply tar, paint, grease or any other material inside the valve as this could impair
performance of the valve.
Installation procedure
The procedure for the installation of Apus solenoid valve when tightening it on a Highpressure CNG system is given below.
j. Remove the thread protection caps.
k. Solenoid valve is “normally closed” in functioning and activates only whenelectric current is passed through the coils.
l. There is a direction arrow indicating the direction of flow of gas when the valve
is activated. The valve shall be connected on the high pressure tube keeping thedirection arrow in mind and ensuring the gas flow and direction arrow are in the
same direction.
m. Male connectors with ¼” NPT (M) end connections shall be prepared and
tightened on the valve.
n. Mount the solenoid valve as per drawing and tighten the mounting nut providedto a torque of 50-65Nm.
o. Connect the 1.5 Ampere super sealed male connector to the female connector of
solenoid valve.
START-UPAfter complete installation of the solenoid valve, check all the connections with the helpof gap inspection gauge, direction of the solenoid valve and check the connection of the
coil with 1.5 Amp super seal connector.
Inlet of Gas Outlet of Gas
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40
APUS SOLENOID VALVE MAINTENANCE PROCEDURE
Filter Replacement
a. In the Apus Solenoid Valve the inlet particle filter must be cleaned at least every50,000 Kms and replace every 100,000 Kms.
b. Bleed out the gas in the system and remove the valve from the lines.
c. Unscrew the inlet fitting of the solenoid valve that has a hex and remove the filter.d. Using standard shop air blow out the filter to clean the residue.
e. Clean out the threads of the inlet fitting and apply on 3-4 threads lubricant Loxeal85-21. Remove any excess amount.
f. Screw the inlet fitting back in the solenoid valve with a torque of 28Nm.
g. Mount the valve again using the mounting nut and tighten it to a torque of 50-65
Nm.h. Connect the male connector back on the tubing line.
Solenoid Coil Change
There is no preventive maintenance required for the solenoid coil. However in case of
damage due to certain adverse conditions it may be necessary to change out the coil. Theinstructions for this are:
a) Disconnect the electrical connections.
b) Unscrew the fixing nut on top of the coil.c) Remove the coil and change it.
d) Caution! Use only original coil supplied by original equipment manufacturer.
Use coil with correct rated voltage and size.e) Apply on 2-3 threads lubricant Loxeal 85-21 and remove excess.f) Re-screw the fixing nut and tighten to a torque of 7Nm.
g) Re-connect electrical cables.
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41
TOOLS AND SPARE PARTS REQUIRED
S.NOTOOLS AND SPAREPARTS REQUIRED
GREENFUELPART NO. PREACAUTION
1Solenoid coil (when it isdamage
GF-69306771
Change thesolenoid coil asper maintenanceprocedure.
2 FilterGF-69988004
Change the filteras per theinstruction given inmaintenanceprocedure
3 Inlet Fitting O-ringGF-FIL-8004
At the time of filterreplacement alsochange the inletfitting o-ring.
TROUBLE SHOOTING DATA SHEET
S.NO PROBLEM CAUSE SOLUTION
1
If solenoid valve isnot working
Current is notflowing in solenoidcoil.
Check all theconnections with the
help of multi meter andif any connection isloose then connect it.
Current is flowing insolenoid coil.
Change the solenoidcoil as per theinstructions given inmaintenanceprocedure.
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42
CHECK VALVE
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43
GENERAL DESCRIPTION
Green fuel offers an advance, high performance no-chatter check valve (TVR1) for usewith natural gas. The main function of this check valve is to prevent the back flow of gas
in the system and also this check valve is designed to minimize the effect of dirt particles
on the sealing components within the unit.This Check valve is constructed of high grade corrosion-resistant steel. TVR1 Check valve is also approved by ECE R110 for an additional safety.
PICTORIAL VIEW
TECHNICAL DATA SHEET
Description Value
Pressure Nominal pressure (PN) 200 Bar
Service pressure (PS) 260 BarTest pressure (PT) 390 Bar
Temperature Working Temperature -40 0C up to +120 0C
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44
INSTALLATION
Storage
A TVR1 Check valve should be stored in a covered area. If covered area is not available,any water proof covering material should be provided over the valve. The check valve
should be kept on a wooden pallet at least 150 mm above the ground level.Do not apply tar, paint, grease or any other material inside the check valve as this could
impair performance of the valve.
Installation procedure
This procedure applies to the mounting procedure of TVR1 non-chatter check valve withboth ¼” OD end connections as well as ¼”OD x ¼” NPT (M) end connections.
a) Remove the check valve from the box.
b) Check valve has an arrow marked on the body indicating the direction of flow of gas.
c) In the reverse direction of arrow the check valve does not allow any flow of gas.
d) Caution! The check valve should be oriented properly to ensure that the flow
direction arrow is the same as the direction of flow of gas.
e) For Check valve with ¼” OD end connections the tube is inserted in the nut andtightened as per standard two ferrules tightening instructions.
f) For check valve with one side NPT (m) end connection the male thread should be
wrapped with Teflon tape prior to tightening.
g) Start wrapping the tape on the check valve thread in the direction of the maletapered thread spiral, and join with a slight overlap.
h) CAUTION: Make sure tape does not overhang the first thread. The tape could
shred and get into the fluid system.
i) Cut-off excess tape and draw free end of the tape and press firmly at the overlay
point.
j) Mount the valve in proper orientation as per vehicle layout drawings.
Inlet of Gas Outlet of Gas
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45
START-UP
After complete installation of the check valve, check all the connections and alwayscheck the direction of check flow is in the direction of gas.
TROUBLE SHOOTING
S.NO PROBLEM CAUSE SOLUTION
1Leakage from theend connection.
Tube fitting is not tightor over tight.
Check it with the gaugeand tight it as per standardinstructions.
Teflon tape is notproperly wrap.
Change the Teflon tape asper standard instructions.
2 Gas is not flowing
Check valve not
oriented properly
Check whether direction ofarrow on body is same as
direction of flow of gas.
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46
PRESSURE TRANSDUCER
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GENERAL DESCRIPTION
The pressure transducer is a device that converts mechanical signals into electrical signalto show the level of fuel left in the gas storage tanks. This device has been separated from
the high pressure gauge to ensure longer and safer performance. The pressure transducer
send an electrical signal to the LED indicator mounted on the dashboard to give thedriver a signal of the amount of gas left in the vehicle.The LED indicator on the dashboard consists of 4 lights, three GREEN lights and one
RED light. When the vehicle is filled up to 200 bar all lights on the LED display unit arelit up. As the gas gets used up the lights keep going off until only the RED light is on.
This is an indication that there is only 40 bar of gas left on the vehicle and the driver musttake the vehicle to the filling station to refuel the gas.
PICTORIAL VIEW
TECHNICAL DATA SHEET
Description Value
Pressure Scale ranges up to 3.5-700 bar
Vibration Range 20 G at 20 TO 200 Hz
Temperature Operating -40 0C to +120 0CCompensated range -20 0C to +85 0C
High Pressure Transducer thatsenses remaining pressure in
CNG cylinders
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48
INSTALLATION
Storage
A pressure transducer should be stored in a covered area. If covered area is not available,
any water proof covering material should be provided over the transducer. The pressuretransducer should be kept on a wooden pallet at least 150 mm above the ground level.
Do not apply tar, paint, grease or any other material inside the transducer as this couldimpair performance of the transducer.
Installation procedure
This procedure applies to the mounting procedure of pressure transducer with both ¼”
OD end connections as well as ¼”OD x ¼” NPT (M) end connections.
p. Cut-off excess tape and draw free end of the tape and press firmly at the overlay
point.
q. Remove transducer from the box.
r. For transducer with ¼” OD end connections the tube is inserted in the nut and
tightened as per standard two ferrules tightening instructions.
s. Start wrapping the tape on the transducer thread in the direction of the maletapered thread spiral, and join with a slight overlap.
t. CAUTION: Make sure tape does not overhang the first thread. The tape couldshred and get into the fluid system.
START-UP
After complete installation of pressure transducer, check all the connections of check
valve.
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49
TROUBLE SHOOTING
S.NO PROBLEM CAUSE SOLUTION
1
Leakage from the
end connection.
Tube fitting is not tight
or over tight.
Check it with the gaugeand tight it as per standard
instructions.
Teflon tape is notproperly wrap.
Change the Teflon tape asper standard instructions.
2If Transducer is not
workingDamage from theexternal sources.
Change the transducer withthe new one as per theinstructions given ininstallation procedure.
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SPARE PART LIST
S.NO
Componentsin TataXenon TML Part No.
DESCRIPTIONOF SPARE
PARTSSUPPLIER
Part No.GREENFUEL
Part No Qty/Pac
1 H.P Filter2186 47700103
WEH makeGrease E99-4 GF-99-E-4 2
WEH makeFilter element E69-79770 GF-69-E-79770 25
Depac glue E-99 DEPAC GF-DEPAC 1
WEH make O-ring of Drain
Plug E50-92167 GF-50-E-92167 25
Circlip E80-93858 GF-80-E-93858 25
WEH makeFilter screw plugO-ring E50-322S568
GF-50-E-322S568 25
WEH makeFilter screw plug
back-up O-ring E55-47144 GF-55-E-47144 25
Filter ScrewPlug tighteningtool GF-F-50-TT-100 1
2TN5 Fillingreceptacle
2896 47709001
WEH makeReceptacle O-ring E50-159S568
GF-50-E-159S568 25
3
Solenoid
Valve
2845 4761
0101
OMB makesolenoid coil of
moon valve 69306771 GF-69306771 10
OMB make inletfilter
69988004 GF-6998800410
OMB make inletfilter O-ring
69306763F GF-FIL-800410
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