Stralis CNG BBI supl.pdf

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STRALIS CNG(COMPRESSEDNATURAL GAS)SUPPLEMENT TO BODYBUILDER

INSTRUCTIONS

EDITION 2010

Publication Edited by:IVECO S.p.A.Technical ApplicationStrada delle Cascinette, 424/3410156 Torino (TO) - Italy

www.iveco.com

Printed 603.95.081 - 1st ed. 02/2010

Publication produced for IVECO bySATIZ TECHNICAL PUBLISHINGc/o Iveco - Customer ServiceLungo Stura Lazio, 1510156 Torino - Italy

Printed 603.95.081 Base - 02/2010

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STRALIS CNGBodybuilders instructionsPrinted 603.95.081 - 1st ed.Base - 02/2010

UPDATE DATA

Section Description Page Revision date

Base - 02/2010 Printed 603.95.081

Update data

This publication provides the data, features and instructions for vehicle fitting and modifications.

It is intended for qualified, skill personnel. The Body Builder is responsible for designing the fitting, its modification and execution,and will have to ensure compliance with the provisions both of this publication and the law regulations in force.

Prior to carrying out any work, make sure you have the publication of the vehicle model on which you are about to work. Also makesure that all the accident-prevention equipment such as, for instance, goggles, helmet, gloves, boots, etc. as well as the working, liftingand handling equipment are available and in goodworking order. Finally, make sure that you operate on the vehicle in such conditionsas to ensure maximum safety.

The execution of the work by strictly complying with the above provisions, as well as the use of the components shown, ensure thatthe work is carried out correctly and safely.

Any change, modification or fitting not covered by this manual and not expressly authorized in written by IVECO will relieve thelatter of any responsibility and make, in particular, the vehicle guarantee null and void.

IVECO is available to provide all and every explanation required to carry out the work and also help you handle the cases not dealtwith in this publication.

After every single intervention, the functioning, efficiency and safety conditions established by IVECO shall be restored. Contact theIVECO service network for vehicle set-up, if necessary.

IVECO shall not be responsible for any change, modification or fitting concerning the vehicle.

The data and information contained in this publication may not be updated due to the changes made by IVECO, at any time, fortechnical or commercial reasons, or to make the vehicles comply with the law regulations in force in the different countries.

In the event of any discrepancy between the contents of this publication and the actual vehicle, please contact the Product Managerfor your market before carrying out any operations.

General danger

It includes the dangers of above described signals.

Danger of serious damage for the vehicle

Partial or complete nonobservanceof theseprescriptions can cause serious damages to the vehicle and sometimes guar-antee lapse too.

Environment protection

It indicates correct behaviour in order that vehicle use is environmentally friendly as much as possible.

Danger for persons

Missing or incomplete observance of these prescriptions can cause serious danger for persons’ safety.

Symbols - Warnings

!

Foreword

It indicates an additional explanation for a piece of information.NOTE

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Foreword

Page header and footer interpretation

Vehicle type Section title Section number -page number

Printnumber

Chapter title Basic edition -month year

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Foreword

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Index of section

INDEX OF SECTION

Section

Guidelines and specifications 1

PTO management 2

This document supplements, but does not replace the 2008 version of the:”STRALIS BODYBUILDERS INSTRUCTIONS”.Each subject not explicity dealt with should be referred them.

NOTE

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Index of section

Guidelines and specifications 1-1STRALIS CNG

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Index

Index

SECTION 1

Guidelines and specifications

Page

1-2 Guidelines and specifications STRALIS CNG

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Index

1.1 General Information 1-3

1.2 Safety Rules 1-4

1.2.1 During refuelling 1-4

1.2.2 In the event of leaks 1-4

1.2.3 In case of fire 1-4

1.3 Operations on the system 1-5

1.3.1 Main components 1-5

1.3.2 General requirements 1-8

1.3.3 Emptying the gas system 1-9

1.3.4 VBE solenoid valve replacement 1-14

1.3.5 Repairs on pipes and unions 1-16

1.3.6 Special requirements 1-17

1.4 Cylinders 1-18

1.4.1 Cylinder scheduled overhauling according to ECE/ONU R 110 standards 1-19

1.4.2 Cylinder replacement 1-20

1.5 Relays / Fuse holder control unit 1-21

1.5.1 Fuse 1-21

1.5.2 Supplementary remote switches 1-24


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General Information

11111.

General Information

1.1 General Information

Natural gas is a mixture that consists essentially of methane (main component), ethane, propane, carbon dioxide and nitrogen.

To make it more recognisable, an odorising agent (THT) is added to give it its characteristic smell of sulphur.

The composition of natural gas may vary considerably, so as a consequence its chemical - physical characteristics may also presentperceptible differences.

Natural gas is compressed in cylinders for transport and use on the vehicle; hence its name of CNG, Compressed Natural Gas.

The CNG versions of the Stralis differ from the other specific solutions applied to some of the engine components through thespecial electronic management and the presence on the chassis of the canisters and piping.

The Fitter must therefore bear in mind the increased technical complexity, both when studying the conversion and above all duringits execution.

!The highly flammable nature of the compressed gas does not allow the vehicles to be fitted out orconverted for fire fighting purposes or for use in potentially critical environments (for example:airports, refineries, etc.)

NOTE IVECO designs, homologates and builds CNG vehicles in compliance with Regulation ECE 110currently in force.

Operations to the engine fuel system that involve different components to those homologated byIVECO (even if they have been homolgated by an Independent Technical Unit) involve the vehiclehaving to undergo rehomologation.

The financial costs of the rehomologation must be borne by the Fitter.

Operations to the engine fuel system that alter the original structure (for example:moving or addingcanisters, the type of canister fastening) should be subject to approval by IVECO.


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Safety Rules

Safety Rules

1.2 Safety Rules

1.2.1 During refuelling

• The gas is usually compressed to 200 bar during refuelling. Small amounts of natural gas may be released during this operation.The cooling that follows its rapid decompression may cause frostbite symptoms if it comes into contact with the skin. Wearprotective gloves during refuelling.

• Do not smoke, handle open flames or flammable lights.

• Before filling the pressurized gas system, check that it has no visible defects.

• Vehicles to be refuelled must be blocked to prevent them from moving. The engine must be off and the ignition key must beextracted from the switch.

• Keep fire extinguishers of suitable class (class A, B, C) with other fire extinguishing devices at hand. Class C fire extinguishersare particularly suitable for methane.

• Avoid releasing the content of cylinders or pressurized gas pipes into the atmosphere.

1.2.2 In the event of leaks

If there are leaks, there is the DANGER OF EXPLOSION so it is important to not only follow all therules set out by the law and competent authorities, to but also observe the following safety rules.!

• Close the shut-off taps on the gas cylinders, the refuelling pump and the refuelling station tank.

• Switch off the main switch of the electric system of the building or refuelling area.

• Block access to the hazardous area and have unauthorized people move away from the area.

• Promptly notify the competent authorities and ask for a restoration operation.

• Ventilate the entire surrounding environment thoroughly.

1.2.3 In case of fire

• Do not extinguish the flame; if possible, cool the object that has caught fire.

• Close the cylinder cocks and the cocks on the filling risers and tanks.

BURNING GAS = GAS UNDER CONTROL

• If the flames spread to the surrounding environment, proceed in the usual manner with fire extinguishers to extinguish the fire.Immediately remove the vehicles from the immediate surroundings from the danger zone.

• In the case of fire, promptly inform the local FIRE BRIGADE and proceeding with the fire extinguishing operations.

• Rescue the injured immediately. Rescue operation come before fire extinguishing.

• Switch off the main switch of the electric system of the building or refuelling area.


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Operations on the system


1.3 Operations on the system

1.3.1 Main components

TankThe gas tank consists of a set of cylinders housed in an appropriate structure secured to the frame.

The number of cylinders and their capacity and installation position depends on the vehicle version.

See paragraph 1.4 for further specific information on the cylinders.

Figure 1.1

1168751. Tank - 2.. VBE safety and shutoff valves

VBE safety and shutoff valvesA valve unit (2, Figure 1.1) is fitted on each canister (1, Figure 1.1) that incorporates the devices listed below:

• Manual closure for maintenance and separation.

• Single-acting solenoid valve dependent on the ignition, which interrupts the flow entering the canister therefore pressurizingshould take place when the solenoid valves are not supplied.

• Flow limiting valve which intervenes, in the case of a sharp variation in pressure, severely restricting the flow of gas out of thecanisters (for example, if one of the pipes breaks).

• Fuse padwhich, in the case of a fire, melts at 103 ± 10 ºC and allows the escape of gas outwards, directly and securely, preventingthe canister from exploding.

!For safety reasons, bothduring fitting out andmaintenance, theuseof gaspipes as fastenings forotherpipes IS PROHIBITED.In special cases,where space is limited, the electrical cables only canbe fastenedto thegas pipes (usingPVC bands) as long as they have a guiding and not supporting function.Take great care during maintenance operations to ensure that the pipes are not damaged and thatthey have no scratches, grooves, cuts or distortions, visible to the naked eye.If necessary, the pipes should be suitably protected.


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The valves are the VBE type, with a tapered attachment thread and they are designed for 70 litre, 80 litre and 140 litre steelcanisters, respectively.

If one of the flow limiting valves or solenoid valves is not working, this may be deceptive as far asthe effective pressurizing status of the canisters is concerned. With this in mind, consult thesolenoid valve checking and replacement procedures in paragraphs 1.3.3 and 1.3.4.

NOTE

The valves are not interchangeable.NOTE

Shut off/check valves

Amanual cock (shut off valve) is located upstream of the system to isolate the gas with the vehicle switched off duringmaintenance.The manual cock must always be closed before working on downstream components (e.g. pressure reducer, engine).

Pipes

All pipes are in annealed stainless steel (316 AISI or 304 AISI), with hardness HRB > 80 (ASTM A269) and without welds.CNG filling plant:

Filler pipe

• External diameter 10 mm or 8 mm depending on optional equipment.

• Stainless steel fittings with double ring of PARKER type (Figure 1.2).

Pipes connecting manifold to VBE cylinder valves

• Diameter 10 mm.

• EMER fittings with cone (Figure 1.3).

Pipes connecting VBE safety valves

• Pipes of external diameter 6 mm.

• EMER fittings with cone (Figure 1.3).

The CNG pipes are mounted to the vehicle�s chassis with metal brackets or mounts. A rubber or PVC spacer is usually fittedbetween the mount and the pipe; this must be in good condition at all times to prevent metal/metal contact.


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Figure 1.2

87386

CONNECTIONS WITH NOSE

Figure 1.3

87387

CONNECTIONS WITH TWIN SEAL


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1.3.2 General requirements

Any change to the system layout will definitely entail re-homologation of the vehicle.NOTE

Observe the following warnings when carrying out operations that are involve fuel system components.

• Before any operation, close the taps on the solenoids of each gas cylinder, then start the engine and leave running until allthe gas in the lines has been used up and the engine stalls.

• Make sure the parts are cleaned, ensuring that no sludge or foreign bodies enter during handling and installation. For thispurpose, the protective caps on the components and sensors must be removed only right before positioning.

• The assembly order must be followed in all electrical connections.

• The components of the feed system cannot be overhauled; if they are inefficient, replace them.

• Minor components must be replaced and systematically restored to their original positions in accordance with the originalinstallation sequence.

After replacement of the valves or after any operation to the high pressure section of the system, theIVECO SERVICE DEPARTMENT should carry out a LEAKAGE TEST (at 300 bar) and, following apositive result, they can issue a test certificate.

!


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1.3.3 Emptying the gas system

!Before performing significant operations (such as welding) or servicing the engine, the gas circuitmustbe completely ventilated with air.

It is usually sufficient to partially empty the system (i.e. to empty the pipes and leaving the cylinders as are) but the entire system(pipes and cylinders) may need to be emptied in some cases.

Decide which procedure is required on a case-by-case basis according to the severity and type of intervention to be performed.If in doubt, choose the safest solution (complete emptying).

If the engine conditions so allow (e.g. no leakages), it is advisable to use up all the gas by running the engine.

Running the engine with system pressure under 20 bar does not ensure the correct fuel metering.

NOTE Below 20 bar, the enginemust be run at idle speed only to prevent damage to the catalytic converter.

!The drainage operation should be carried out with the engine switched off, in an area where they areno sources of possible flames within a radius of at least 5 metres surrounding the vehicle.

To partially discharge the circuit, proceed as follows:• shut off power to the vehicle’s electrics at the master power switch;• disconnect the battery cables and connect them to each other to discharge any residual charge;• ground the vehicle;• check that the cocks (1) on all cylinders are closed;• connect a rubber hose (methane compatible) to the terminal (3) of the ventilation valve (2) to dispose of the gas. The freeend of the hosemust be at least 5mdistant from any source of sparking or open flame;

• slowly open the ventilation valve (2). During this operation the cooling due to fast decompression may cause icing: take allsuitable precautions;

• check that pressure gauge (4) is reading zero circuit pressure.


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Partial emptying procedureFigure 1.4

116876

!This operation only guarantees the ventilation of the system downstream of the canisters. Thereforeit is vital to make sure that no work is carried out within a distance of 5 metres of the canisters, thatcould produce sparks (welding, cutting, grinding, drilling) or that involves the use of equipment with anelectrical power supply or that uses naked flames.

NOTE If there is a second group of canisters, the previous operations should be repeated on it.

Complete emptying procedure

When the system is fully drained down, the cylinders must also be ventilated. To allow the gas to be evacuated in safety, removethe VBE valve plungers and the system must be ventilated downstream of the manual cylinder taps.

• Proceed with the partial emptying procedure described in the paragraph above;

• Close ventilation valve (2);

• Check that solenoid cocks (1) on all cylinders are closed and proceed as follows.


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VBE solenoid valve plunger extraction

Figure 1.5

117660

• Disconnect the electrical connection from the coil.• Unscrew the outer nut of coil (1) with its O-Ring (2);

Figure 1.6

117661

• With a screwdriver (1), stop rotation of the threaded pin (4) and use tool (2) to remove the nut (3) fastening the coil (5). Removethe coil (5) from the sleeve (6).

Figure 1.7

117662

• Remove the washer (4).

A small amount of high-pressure gas will remain in the valve.To prevent damage to the operator, it is advisable to decrease the pressure by slowly unscrewing ringnut (2) from the coil sleeve (1).

!

• With no residual pressure, proceed with the disassembly procedure and remove the coil holder sleeve (1) with its O-Ring (3).


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Figure 1.8

87391

• Remove the piston (5) with shutter (4) and the spring (2) from the coil holder sleeve (1) being very careful not to misplace thepin (3) fastening the shutter to the piston.

• If the VBE valves do not need to be replaced, check the conditions of the removed parts, including the o-rings. Replace themif needed during assembly.

• Fasten the empty coil holder sleeve with its o-ring and fasten the ring nut at a torque of 28 Nm.

• Repeat the operations on all the VBE valves of the cylinders.

Emptying

• Open the manual valves half way (1) (Figure 1.4).

!This operation ensures that pressurised gas enters the pipes: for this reason, exercise maximum care.

After disposal operations, check that the engine cannot stop.

If the VBE valves are not replaced after the complete emptying procedure, refit the previously removed parts (which were eithercarefully put aside or replaced) as shown in the following paragraph.


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Introduction to solenoid valve plunger

Remove the empty coil sleeve (1) with the o-ring.

Figure 1.9

87391

• Insert the piston (5) in the shutter (4) and lock it with the pin (3).

• Insert the spring (2) and push well into the specific seat in the piston (5).

• Fit the resulting assembly into coil sleeve (1) with the tapered part of plunger (4) turned toward the outside of the coil carriersleeve.

• Check the presence and conditions of the o-ring on the sleeve (1).

Figure 1.10

87392

• Fasten the coil holder sleeve ring nut and tighten at a torque of 28 Nm.


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Figure 1.11

117663

• Check that coil (4) does not present signs of damage. If necessary, perform the checks described in the chapter ”VBE valvefunctional inspections and servicing” and replace the coil, if needed.

• Fit the washer (4, Figure 1.7) and the coil (4, Figure 1.11) on the sleeve (1, Figure 1.7).• Screw in inner nut (3) securing coil (4) and tighten to 8 Nm.• Screw in nut (1) with o-ring (2) and tighten and tighten to a torque of 7 Nm.• Connect the electrical connection to the coil (4).• Repeat the previous operations on all VBE valves of the cylinders.

1.3.4 VBE solenoid valve replacement

Removal

The VBE valves can be removed following a failure or during the regular overhauling of the canisters.The valves that have been removed cannot be reused therefore they should always be replaced,whatever the reason they have been removed. It is advisable to scrap them straight after they havebeen removed.

NOTE

!Before disconnecting the solenoid valves, the system must be completely drained following theprocedure described in the “Draining the gas system” chapter.

Figure 1.12

116878

• Remove the screws (1) and remove the cover (2).


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Figure 1.13

116879

• Loosen the fittings (1 and 3) and disconnect the pipes (2 and 4) from the VBE valve fittings (5). Disconnect the electricalconnection (8) from the coil (6).

Figure 1.14

116880

• Use tool 99355018 (2) to loosen and remove the VBE valve (1) from the cylinder (3).

Refitting

Reverse the removal sequence to refit and observe the following precautions:

• the VBE valve protective caps must not be removed to avoid damage to the valve during assembly. The use of percussionpneumatic screw runners or of any other tool which could deform the valve body and compromise functionality must be avoided.

• if the cylinder is off-vehicle, secure the cylinder preferably in vertical position with the collar facing upwards.

• fasten the threading of the valve seat with 2-3 layers of Teflon.

• tighten the valve, by hand, through several turns. Then, using the special spanner 99355018 (2) together with a torque wrench,tighten to a torque of 270 ±10 Nm.

In this operation, make sure that tool 99355018 (2), does not damage the VBE valve thermal fusedevice.

NOTE


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1.3.5 Repairs on pipes and unions

CNG fuel pipe assembly instructions

• Apply 5 turns of teflon on the free threads of the tapered unions before assembling.

• Themetal pipe will be inserted into the corresponding union without slackening or removing the ring nut to prevent the nosesfrom falling.

• The check to ensure that the pipe is correctly positioned in the connector is carried out using a suitable gauge.

• The tightening torque of the M12x1 threads is 25 Nm.

• The tightening torque of the 1/4 G threads is 30 Nm.

• The tightening of the ring nuts of the unions must be done by hand applying a torque of:- for pipe Ø 12x1.5 = 60 - 65 Nm- for pipe Ø 10x1 = 40 - 45 Nm equivalent to 1 + 1/4 turns- for pipe Ø 6x1 = 18 - 20 Nm }

System with tapered nose double connectorsIf leaks of gas are noticed from the pipe or the connectors, the complete pipe has to be replaced. The pipe is not supplied

with connectors (Figure 1.2) so they will have to be obtained separately.

• Undo the unions from the parts requiring connection with the pipe and apply the new ones. The unions are suppliedassembled and ready for use.

• Check the condition of the pipe and fit it to the unions, making sure it is fully inserted. To avoid prestressing, always checkthe alignment of the end of the pipe with the unions.

• Screw the unions’ nuts down hand tight. Mark the position of the nut relative to the union body.

• Use two wrenches working in opposite directions to tighten the nut down a turn and a half. This compresses the cone packand crimps the pipe.

• Fit the brackets making sure not to stress the pipe.

• Restore system operation by running the hydraulic seal test as described elsewhere.

Connection of connectors following the simple disconnection of the pipe

• Check the condition of the union and the cones.

• Fit the end of the pipe into its seat in the union. To avoid prestressing, always check the alignment of the end of the pipewith the union.

• Tighten the union�s nut down by hand until the two cones are packed together. Mark the position of the nut relative tothe union body.

• Use two wrenches working in opposite directions to tighten the nut down half a turn. This wedges the second cone underthe first and tensions the seal unit.

• Fit the brackets making sure not to stress the pipe.

• Restore system operation by running the hydraulic seal test as described elsewhere.


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1.3.6 Special requirements

A) Replacement of minor components

• Fuel system components cannot be serviced and must be replaced if they are not efficient.

• Washers, tapered washers, self-locking nuts and seals deform to improve tightening and they are also of a special type. Theymust therefore be replaced during every refitting.

• New minor components must be systematically restored to their original positions in accordance with the original installationsequence.

B) Repainting of outfitted framesThe paintwork must be protected

• the methane fuel system stainless steel pipes.

• the connectors for the pipes.

• the flexible pipe from the pressure reduction unit to the rail on the engine.

• the solenoid valves and the coils on the gas canisters.

• the gas system pressure reduction unit.

• the identification plates.

C) Engine control unit protection

Figure 1.15

142793

On Stralis CNG vehicles, engine control unit (1) is positioned on the rear cab suspension crossmember, in a central position.

If the vehicle conversion operation means that the engine exhaust gas pipe runs vertically behind the cab, the pipe must be keptsufficiently far away from the control unit to avoid problems of induced overheating.This distance must never be less than 50 mm.


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Cylinders

Cylinders

1.4 Cylinders

Figure 1.16

116886

Themethane (CNG) is stored in compressed form at a pressure of 200 bar in a certain number of cylinders positioned in the chassisand protected by metal guards.The cylinders are connected in series to each other and are filled by a refuelling valve provided with check valve. A second checkvalve is inserted in the solenoid valve fitted on the first cylinder and connected to the refuelling filler. The check valves are used toprevent the release of gas into the outside environment when the valve is extracted after the refuelling operation.

A faulty flow valve or solenoid valvemay lead to incorrect indications regarding the cylinder contents.Refer to the solenoid valve inspection and replacement procedures in the corresponding paragraph1.3.4.

NOTE

Important information concerning the cylinders is punched into their upper surface (o).

CNG ONLY - DO NOT USE AFTER

01/1234/ 123 = FABER serial numbers

CNG-I USE TESTED FABER CYLINDERS ONLY

FABER 01/1234/123 MPaE15°C/KG

(9) (10)

(3) (4) (5)L

(6) (7)110R-

(8)

(1) (2)

(1) = expiration month,(2) = expiration year, after 20 years(3) = nominal capacity(4) = cylinder weight(5) = working pressure in MPa(6) = test pressure in MPa(7) = country where the cylinder was approved(8) = ECE/ECE type approval number(9) = test month/year(10) = inspector punch


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Cylinders

1.4.1 Cylinder scheduled overhauling according to ECE/ONU R 110 standards

Methane gas cylinders for road vehicles must be inspected EVERY FOURYEARS by competent authorities responsible for certifyingtheir validity.

NOTE The due date is shown on the cylinders and in the documents supplied with the vehicle.

ECE/ONU R 110 specify the following procedure to be followed in the event of an accident:

• cylinders that have been involved in a vehicle collision (frame) must be inspected by an agency authorised by the manufacturerunless the competent authorities decide otherwise. A cylinder that has not suffered any damage following the collision impactcan be returned to service; otherwise the cylinder must be sent back to the manufacturer for examination;

• cylinders that have been subject to the effects of a fire must be inspected by an agency authorised by the manufacturer orscrapped and removed from service.

• Remove the VBE valves (10) as described elsewhere.

• Remove: screws (4 and 12), nuts (13) and remove the brackets (2 and 11).

• Fit a harness to the top cylinder (1) and raise it with a hoist (1). Do the same for the other top cylinder.

• Remove the nuts (7) and fold down the brackets (6).

• Remove the lower cylinders (5) in the same way as the top ones.

Replacing cylinders

To refit, reverse the order of the operations described for the removal, observing the following warnings:

• Place the cylinders in the framework with the VBE valves pointing in the right direction, making sure that no metal parts arein contact with the cylinder casings.

• Check the condition of the pipes, unions and - cones. If damaged in such a way as to affect - their tightness or strength, replacethe pipe and unions.

• Fit the pipe into the valve seat,with the cylinder oriented in such a way as to avoid prestressing the pipe.

• Hold the pipe in position and screw in the union to 25 ± 5 Nm.

• Once reinstalled, run the circuit hydraulic seal test.


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Cylinders

1.4.2 Cylinder replacement

Removal

!Before disconnecting the cylinders, empty the system completely following the procedure describedin the ”Methane system emptying” chapter.

Figure 1.17

143782


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Relays / Fuse holder control unitRelays / Fuse holder control unit


1.5 Relays / Fuse holder control unit

1.5.1 Fuse

Figure 1.18

126166

Black color fuse holder (70601)Ref. Function Delivery (A) Terminal1 Terminal 15 for air conditioning / Heated prefilter / Radio 24V 5 +15

2Food warmer + Fridge / BM (Bed Module) / Diagnosis connector / OBDconnector 10 +Batt

3 Tachograph / IC / Centralized locking (remote control) 5 +Batt4 SWI (Steering Wheel Interface) 5 +305 Cigar lighter - 24 V/12 V voltage reducer / Radio 24 V 20 +306 Tilted cab / Drier / Water presence in fuel filter / ”Shut off” solenoid valve/

Projectors positioning10 +15

Red color fuse holder (70602)Ref. Function Delivery (A) Terminal1 ACC (Adaptive Cruise Control) / Allison gearbox 10 +152 Eurotronic II / Fan electromagnet coupling / Allison gearbox 10 +303 Internal lighting / Tool compartment lights 5 +304 EBS / ABS - D BASIC 5 +155 EBS 15 +306 EBS / ABS - D BASIC 15 +30

Natural color fuse holder (70603)Ref. Function Delivery (A) Terminal1 Driver’s door module (DDM) / driver’s electric window without DDM/PDM 20/15 +30/+15

2Passenger door module (PDM) / passenger’s electric window withoutDDM/PDM 20/15 +30/+15

3 IC (Instrument Cluster) 10 +154 CNG (Methane fuel system power supply) 30 +305 Body Computer 25 +306 Body Computer 25 +30


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126166

Figure 1.19

Black color fuse holder (70604)

Ref. Function Delivery (A) Terminal1 EM (Expansion Module) 15 +302 Air-conditioning system 15 +303 Air-conditioning system / IT / Navigation 5 +304 Auxiliary heating 15 +305 Auxiliary heating 5 +306 VCM (Vehicle Control Module) 20 +30

Natural color fuse holder (70605)

Ref. Function Delivery (A) Terminal1 EM (Expansion Module) 15 +302 Vehicle levelling 5 +153 Chassis level adjustment 7.5 +304 Decelerator with CAN / Headlight washer 10 +305 Decelerator with CAN / Retarder / Mirror heating 15 +156 Heated seat / Central lubrication / IT / navigation / Centralized locking 7.5 +15


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126166

Figure 1.20

Black color fuse holder (70401)Ref. Function Delivery (A) Terminal1 Cab tilting 25 +302 Cab tilting 5 +303 Body builders 10 +304 Heated windscreen 25 +30


Ref. Function Delivery (A) Terminal1 Heated windscreen 25 +30

212 V internal lighting / 12 V Reading lights / Navigation system / Telematicsystem 5 -

3 - - -4 K15 for alternator 5 +15


Ref. Function Delivery (A) Terminal1 EM 10 +302 EM 10 +303 EM / ACC 5 +154 CNG (12V power supply for MF3 control unit and flow meter) 5 +


Ref. Function Delivery (A) Terminal1 Trailer ABS/EBS 10 +152 Sunblind 7,5 +153 CNG (Power supply for MF3 control unit) 5 +304 CNG (Supply for solenoid valves for canisters) 20 +30


Ref. Function Delivery (A) Terminal1 CNG power supply of spark plugs 5 +152 CNG power supply of spark plugs 5 +153 CNG (Power supply for MF3 control unit) 15 +15

4CNG (Supply for Lambda sensors, waste gate solenoid valve and pressureregulator solenoid valve) 10 +15


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1.5.2 Supplementary remote switches

Figure 1.21

126166

Ref. DescriptionComponentcode

A Fan electromagnet coupling relay 25737B Water heater remote control switch 25337

C Allison gearbox remote-control switch AT/AD 25210D Manual air conditioner remote-control switch 25332E Water heater remote-control switch 25325

F Allison gearbox remote-control switch AT/AD 25609G Manual air conditioning remote-control switch (CNG) 25752AH Diodes for cab tilting 61000B

I Manual air conditioning remote-control switch 25874K Manual air conditioning remote-control switch 25310L Remote control switch for IGC 25903

M Manual air conditioning remote-control switch 25322N Manual air conditioning remote-control switch 25332BO Engine disengagement relay (CNG) 25752B

P Manual air conditioning remote-control switch 25327R Manual air conditioning remote-control switch 25332A

S Remote control switch 12 V terminal 15 (CNG) 25751

73672

113554

Figure 1.22

Figure 1.23


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Remote-control switches

a) Positioned behind the BODY COMPUTER.


GA Gas cylinder solenoid valve remote control switch (CNG) 40A 25921GB Remote-control switch (terminal 15), 50A 25213GC Starting remote-control switch (50), 40A 25200GD Remote control switch for supply (CNG) 40A 25918GE Cabin tilting remote-control switch 25906GF Cabin tilting remote-control switch 25722GG Cabin tilting remote-control switch 25723

b) Positioned in the control unit compartment.


BA Headlight washer enablement relay 25740BB - -BC - -BD - -


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PTO management 2-1STRALIS CNG

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Index

Index

SECTION 2

PTO management

Page

2.1 Introduction 2-3

2.2 Mechanical Power Take-Off (PTO) installation, maximum power take-off 2-4

2.2.1 Physical torque and speed limits 2-4

2.2.2 Normal PTO operation - green zone 2-5

2.2.3 Full power PTO operation - blue zone 2-5

2.2.4 PTO during driving - yellow zone 2-6

2.3 Electronic PTO setup 2-7

2.3.1 Expansion Module (EM) 2-7

2.3.2 Vehicle Control Module (VCM) 2-7

2.3.2.1 Advanced settings - PTO modes 2-7

2.3.2.2 Advanced settings - Body assembler 2-8

2.3.2.3 PTO Mode 1...3 2-9

2-2 PTO management STRALIS CNG

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Index


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Introduction

22222.

Introduction

2.1 Introduction

IVECO Compressed Natural Gas (CNG) engines are Spark Ignition engines working in Otto process.

They use stoichiometrical air/fuel ratio for combustion in any operation point. The power of the engine is not controlled by fuelinjection quantity like in a Diesel engine, but by air flow through the engine. The reaction times are therefore slightly delayedcompared to a Diesel engine. This reduces rpm control quality in response to varying load.

This Bodybuilder Instructions appendix was made to explain the precautions to be taken and thelimitations to be respected when installing a Power Take-off (PTO) on a CNG engine.

NOTE


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Mechanical Power Take-Off (PTO) installation, maximum power take-off

Mechanical Power Take---Off (PTO) installation, maximum power take---off

2.2 Mechanical Power Take-Off (PTO) installation, maximum power take-off

Any type ofmechanical PTO installation known forDiesel engines (chapters 4-1 to 4-5 of IVECO Stralis Bodybuilder Instructions)is also suitable for CNG engine, if the respective gearbox/driveline configuration is available.

2.2.1 Physical torque and speed limits

Normally the engine torque in PTO operation must not exceed the torque that the engine can deliver in atmospheric operation(= “without help of the turbocharger“). Like this, it can be guaranteed that the engine can react in a relatively quick way to the needof torque variation.

Figure 2.24

142794

engineoutputtorque(Nm)

engine speed [rpm]

PTO max torque

max torque 200 kW

Therefore, three PTO operation zones are defined for a CNG engine (see next page).

Note that all torque and rotational speed values mentioned in these chapters refer to the engine clutch output side. If the installedPTO has a transmission ratio (which is virtually always the case), the torque @PTO can be calculated multiplying the values men-tioned here by the transmission ratio, the rotational speed@PTOmay be calculated by dividing the output values by the transmissionratio.


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2.2.2 Normal PTO operation - green zone

From 900 rpm to 1300 rpm (engine output rotational speed)From 0 Nm to 550 Nm of PTO torque application (calculated on engine output)Engine operates in PTO mode 1, 2 or 3 using an engine speed control target value of 900 rpm to 1300 rpm.The vehicle is in standstill, gear is disengaged (= neutral), driving is impossible, accelerator pedal is disabled.The PTO load is the only load that is applied to the engine.The PTO load may be applied earliest 0.3 seconds after engine speed control target active.

2.2.3 Full power PTO operation - blue zone

From 1000 rpm to 1300 rpm (engine output rotational speed)From 550 Nm to engine max torque applied by PTO (calculated on engine output)Engine operates in PTO mode 1, 2 or 3 using an engine speed control target value of 1000 rpm to 1300 rpm.The vehicle is in standstill, gear is disengaged (= neutral), driving is impossible, accelerator pedal is disabled.The PTO load is the only load that is applied to the engine.The PTO load may be applied earliest 0.5 seconds after engine speed control target active.PTO operation in this zone requires soft start function and smooth operation control:Soft start• The body must not raise PTO torque quicker than 50 Nmper second (in order to avoid engine stall). This means that full torque(1100 Nm) can be reached earliest after 22 seconds.

Smooth operation control• The body must avoid any significant variation of PTO torque - it is in the responsibility of the Bodybuilder to avoid engine speedoscillations with amplitude greater than +/- 50 rpm and engine speed accelerations greater than +/- 100 rpm/s.

Figure 2.25

enginespeed[rpm]

rpm rpm/s

engine speed [rpm]

engine speed setpoint [rpm]

time [s]

If these limits are exceeded, engine malfunction and catalyst overheating with risk of fire and/or severe damage of the vehicle canoccur. IVECO can not be held liable for any damage caused by inadequate PTO torque/power consumption in “full power PTOoperation - blue zone”.


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2.2.4 PTO during driving - yellow zone

From 700 rpm to 2300 rpm (engine output rotational speed)

From 0 Nm to 400 Nm PTO torque application (calculated on engine output)

From 0 kW to 35 kW PTO power request.

Engine operates in PTO mode 1, 2 or 3 using no engine speed control target value, but only a low engine speed limit between 700rpm and 800 rpm.

A high engine speed limit may be applied, but not below 1800 rpm.

The vehicle may also be driven with PTO engaged, accelerator pedal is enabled

The PTO load is applied in addition to the normal engine load by driving.

The PTO load may be applied earliest 0.5 seconds after low engine speed limit active.

In case of torque request > 200 Nm, a “soft start” function is required (additionally to all conditions mentioned above) in orderto avoid engine stall. The body must not raise PTO torque quicker than 50 Nm per second.

/


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Electronic PTO setup


2.3 Electronic PTO setup

Using customer service tool EASY, the PTO configuration can be set.

2.3.1 Expansion Module (EM)

The setup of the EM shows no difference to Diesel engine applications, chapter “4.6.2 PTO modes” of the IVECO Stralis Body-builder Instructions is fully applicable.

2.3.2 Vehicle Control Module (VCM)

The setup of the VCM shows significant differences to Diesel engine applications.

Concerning the PTOmode 0 (driving mode), there is no difference to Diesel engines, chapter “4.6.3.1 RPM 0mode (driving mode)”of IVECO Stralis Bodybuilder Instructions is valid.

Chapters 4.6.3.1 to 4.6.3.6 of IVECO Stralis Bodybuilder Instructions are only valid for CNG engines, if the respective item is nottreated here.

The VCM PTO programming has the following tree structure

Figure 2.26

Programming by alphanumeric code is not treated here.Detailed programming (= entering every setting manually) is the normal application case.

2.3.2.1 Advanced settings - PTO modes

Figure 2.27

The settings in this chapter are generic for all PTO modes.

The following values have to be set.


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Table 1

English description in EASYtool setting instruction

Engine speed increase/decrease viaSET+/SET-

depends on application - use set-tings like for Diesel engine

Time to reach the selected engine revs 0,1 sec

Disabling speed for external enginerequest


Disabling PTO mode during thechange of CC management external/-internal or internal/external


Temporary engine speed increase onexpansion module request

OFF

Max. Revs (high idle) that can bereached by engine in case of CANkickdown

not used

Temporary engine speed increase ondriver request by expansion module

OFF

Max. Revs (high idle) that can bereached by the engine in case ofDriver’s kickdown

not used

Engine idle shut-off requested byexpansion module according to thespeed


Speed for P.T.O. disablingdepends on application - use set-tings like for Diesel engine

Re-activation speeddepends on application - use set-tings like for Diesel engine

2.3.2.2 Advanced settings - Body assembler

Figure 2.28

The advanced body builder interface settings are not CNG specific and can be used like in a Diesel vehicle.


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2.3.2.3 PTO Mode 1...3

The structures of the settings for PTO MODE 1, PTO MODE 2 and PTO MODE 3 are identical.

For each PTO mode, the following settings are possible.

Table 2

english description in EASY tool

Setting instructionNormal PTO operation

green zonePTO during driving

yellow zonereal meaning ofparameter

Full power PTO operationblue zone

standard settingsEnable for maximum engine speed that can be set byaccelerator pedal

OFF OFF

Maximum engine speed that can be set by acceleratorpedal

high engine speed limit(applied always in this PTOmode)

1150...2300 rpm250 rpm (or more) higher thanengine speed control targetvalue

1800...2300 rpm

Minimum speed that can be set by set - (WARNING:do not exceed 150 rpm of Idle Engine Speed)

low engine speed limit(applied always in this PTOmode)

700 rpm 700...800 rpm

Maximum Torquedo not modify(default 2500 Nm)

do not modify(default 2500 Nm)

Maximum engine speed that can be set by SET+

high engine speed limit(applied always in this PTOmode)

1150...2300 rpm250 rpm (or more) higher thanengine speed control targetvalue

1800...2300 rpm

cuve slopehigh engine speed control-ler feedback factor

0 0

Speed Threshold for PTO/Cruise Control Activationdepends on application - usesettings like for Diesel engine

15 km/h

PTO Shut-Off when Parking brake is OFFdepends on application - usesettings like for Diesel engine

ON

Activation of the parameter for the maximal PTOSpeed

depends on application - usesettings like for Diesel engine

ON

Maximum PTO Speeddepends on application - usesettings like for Diesel engine

2 km/h

PTO Shut-Off by pressing the brake pedaldepends on application - usesettings like for Diesel engine

ON

PTO Shut-Off via engine brake request by the driverdepends on application - usesettings like for Diesel engine

ON

PTO Shut-Off via Intarder by the driverdepends on application - usesettings like for Diesel engine

ON

PTO Shut-Off via CAN engine brake requestdepends on application - usesettings like for Diesel engine

ON

PTO Shut-Off via CAN Intarder requestdepends on application - usesettings like for Diesel engine

ON

PTO Shut-Off by pressed clutch pedaldepends on application - usesettings like for Diesel engine

ON

PTO Shut-Off when revs are lower than minimumspeed hat can be set by SET -

OFF OFF

PTO Shut-Off when revs are higher than maximumspeed that can be set by SET +

OFF OFF

PTO Shut-Off in case of error on Cruise Control Moduledepends on application - usesettings like for Diesel engine

ON

Check on fault of switches for service and parking brakedepends on application - usesettings like for Diesel engine

ON


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22222.

english description in EASY tool

setting instructionNormal PTO operation

green zonePTO during driving

yellow zonereal meaning ofparameter

Full power PTO operationblue zone

Standard settings

Accelerator Pedal Disablingaccelerator pedal deactiva-tion during this PTO mode

ON(accelerator pedal deactivated)

OFF(accelerator pedal active)

Resume Function at Startingengine speed control auto-matically engages whenengine is switched on

depends on application - use set-tings like for Diesel engine OFF

Keeping the Resume Function by other PTO modesengine speed control auto-matically engageswhen swit-ching to this PTO mode

depends on application - use set-tings like for Diesel engine OFF

PTOShut-Off in case of error on vehicle speed sensor ON ON

PTO Shut-Off by external requestdepends on application - use set-tings like for Diesel engine ON

Shut-off conditions in case of error on vehicle speedsensor

depends on application - use set-tings like for Diesel engine ON

PTO Shut-Off via coolant temperature control OFF OFFCoolant Temperature Not used Not usedPTO Shut-Off with engaged gear ON ONPTO Shut-Off with engaged reversing gear ON Not usedActivation of the control on the lowest gear toengage/shut off the PTO

depends on application - use set-tings like for Diesel engine Not used

Lowest gear to engage/shut off the PTOdepends on application - use set-tings like for Diesel engine Not used

Activation of the control on the highest gear toengage/shut off the PTO

depends on application - use set-tings like for Diesel engine Not used

Highest gear to engage/shut off the PTOdepends on application - use set-tings like for Diesel engine Not used

PTOmode disabling via OFF key of the cruisemoduledepends on application - use set-tings like for Diesel engine ON

Cruise Control and MEMO Function Management

enginespeedcontroladjust-ment possibilities for the dri-ver (via cruise control but-tons)

Set to “without calibration”Set to “without calibra-tion”

Engine Speed Range via MEMOengine speed control targetvalue

900...1300 rpm (green zone)1000...1300 rpm (blue zone)250 rpm (or more) lower thanhigh engine speed limit

Not used

Maximum Speed via SET+vehicle speed limit to switchoff engine speed control 2 km/h 2 km/h

Temporary Engine Speed Increase by other ECUEuroTronic can overrideengine peed limit OFF OFF

Temporary Engine Speed Increase by driver requestAccelerator pedal kickdowncan override engine speedlimit

OFF OFF

Customized settings

Replace Speed EnableUse a special vehicle speedlimit in this PTO mode


depends on application -use settings like forDieselengine

Replace Speed ValueVehicle speed limit value forthis PTO mode


depends on application -use settings like forDieselengine

ISC Parameter Set indicationdo not modify(default 7)

do not modify(default 7)

Torque Limitation depending upon engine revs(REVS) do not modify

(default 2500 Nmat any engine speed)

do not modify(default 2500 Nm at anyengine speed)

Torque Limitation depending upon engine revs(TORQUE)

Documents

Stralis CNG BBI supl.pdf