DTC Marcopolo Manual

8/3/2019 DTC Marcopolo Manual

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OPERATION AND MAINTENANCE

MANUAL

FOR

TATA MARCOPOLO

HIGH PRESSURE CNG SYSTEM & COMPONENTS



2

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



3

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



4

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.



5

CIRCUIT DIAGRAM

NOTE:GREENFUEL SCOPE OF SUPPLY:

1. Cylinder valve

2. Solenoid valve3. Check valve4. Pressure gauge5. Receptacle6. Filter7. Transducer



6

BETA NEW CYLINDER VALVE



7

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



8

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



9

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



10

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.



11

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.



12

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



13

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.



14

TN5 FILLING RECEPTACLE



15

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



16

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.


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.


(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.



17

(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)



18


S.NO. DESCRIPTION PART NO. PRECAUTION

1 O-ringGF-50-E-159S568

Always use the WEH makeoriginal O-ring for the

receptacle



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.



19

H.P FILTER



20

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



21

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.



22

(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.


Description Value

Pressure Nominal pressure (PN) 200 BarService pressure (PS) 260 Bar

Test pressure (PT) 390 Bar


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.


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



23

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.



24

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.



25

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.



26

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.



27

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.



28


S.NO

TOOLSAND

SPARE

PARTSREQUIRED

WHEN

REQUIRED TOCHANGE


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



29



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).



30

PRESSURE GAUGE



31

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.



32


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.



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



33

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.



34

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



35

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


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.



36

APUS SOLENOID VALVE



37

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



38

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.


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



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.


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



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.



41

TOOLS AND SPARE PARTS REQUIRED

S.NOTOOLS AND SPAREPARTS REQUIRED


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.



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.



42

CHECK VALVE



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


Description Value

Pressure Nominal pressure (PN) 200 Bar

Service pressure (PS) 260 BarTest pressure (PT) 390 Bar




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.


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



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


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.



46

PRESSURE TRANSDUCER



47

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


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



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.


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.



49

TROUBLE SHOOTING


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.



50

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



Documents

DTC Marcopolo Manual