OPERATION AND MAINTENANCE MANUAL

FOR TATA MARCOPOLO HIGH PRESSURE CNG SYSTEM & COMPONENTS

INDEX
S.NO 1 DESCRIPTION CNG System and components PAGE NO. 3

2 3 4 5 6 7 8 9 10 11 12

Safety standards used in CNG system Do's and Donts of CNG system Circuit diagram of CNG system Beta new cylinder valve TN 5 Receptacle H.P Filter Pressure Gauge Apus Solenoid valve Check valve Transducer Spare Part List

4 4 5 6 14 21 30 36 42 46 50

Compressed Natural Gas (CNG)

Compressed Natural Gas is a clean and economical alternate fuel for vehicles. There are more 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 is because 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 a higher 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 which natural 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 and explode 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 are components 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 gas to 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

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 Dos

Always Inspect joints etc. under pressure for leaks and proper installation after reinstallation. 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- Donts

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.

CIRCUIT DIAGRAM

NOTE: GREENFUEL SCOPE OF SUPPLY: 1. Cylinder valve 2. Solenoid valve 3. Check valve 4. Pressure gauge 5. Receptacle 6. Filter 7. Transducer

BETA NEW CYLINDER VALVE

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

CONSTRUCTION
Beta new valve consists of following components. (1) Excess flow device This 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 gas pressure 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 the path 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 and closing. In addition there are also the letters O marked for opening and C for closing.

Cylinder Valve hand wheel with open and close positions marked

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 valve knob from its stop position.

TECHNICAL DATA SHEET

Description Pressure Maximum working pressure Test pressure Hydraulic collapse pressure Temperature Working Temperature PRD activation temperature

Value 260 Bar 275 Bar >800 Bar (without burst disc) -40 to +85 0C 108 6 0C 38,5 mm2 104 sec.

P.R.D safety device

Minimum area of gas flow Empty tank time (Volume=100 liters/ Pressure=220 bar P.R.D activation time (Fire directed on P.R.D) Minimum area of gas flow Burst pressure (at room temperature) Minimum area of gas flow Tightening torque at 360 bar opening/closing angle Pressure difference valve activation

10 sec. 12,6 mm2 300 bar+10% 28,3 mm2 4 1 N-m 3600 900

Burst disc

Manual valve Manual tap

Excess flow

6,5 Bar

INSTALLATION OF BETA NEW VALVE

Storage Beta new 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 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 cylinder thread 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 free from irregular burrs or edges. d) Use a suitable Teflon tape (minimum density of 1.2 g/cc); start wrapping the tape on the cylinder valve thread in the direction of male tapered thread spiral, and join with a slight overlap.

10

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 free from irregular burrs or edges.

h) Manually insert the valve thread into the cylinder neck and screw manually till the threads do not engage further.

11

i) Using a torque wrench and correct tool fixture for the cylinder valve. Tighten the valve to a torque value between 200-300 Nm.

Tightening tool of beta new valve

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.

12

TOOLS AND SPARE PARTS DATA SHEET

S.NO TOOLS AND SPARE PARTS REQUIRED GREENFUEL PART NO. PREACAUTION Tighten the valve to a torque value between 200-300 Nm. Make sure that tape does not overhang the first thread.

Torque wrench and 1 Tightening tool

GF-200-TT-B

GF-S-STR-4

2 Teflon Tape

TROUBLE SHOOTING DATA SHEET

S.NO PROBLEM CAUSE SOLUTION

Leakage through cylinder threads

In case of activation of PRD devices

If gas is not coming from the cylinder

In case of over tightening, the valve threads will be damaged. Change the valve with a new one and install it as per the instructions. Over tightening Unwrapped the Teflon tape and again wrap a new Teflon tape as per Teflon tape is not instructions (d), (e) and properly wrapped (f). Change the cylinder valve and do not attempt Due to high to re-use the same pressure or valve. temperature. 1. Close the cylinder valve and wait for Excess flow device is activated 15-20 mins. 2. Slowly open the because of pressure difference cylinder valve.

13

TN5 FILLING RECEPTACLE

14

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 the vehicle. The filling receptacle gets locked in with the filling nozzle at the filling station and 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 the vehicle it does not make any chatter or noise.

PICTORIAL VIEW
Panel mount nut

O-ring

Two-Ferrule end connection

15

CONSTRUCTION
(1) Check valve In a TN-5 receptacle, an inbuilt check valve is provided. This inbuilt check valve ensures there is no back flow of gas. (2) O-ring The o-ring within the receptacle should be specially designed to withstand the harsh environment 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 abrasion and it has a longer service life.

TECHNICAL DATA SHEET

Description Pressure Nominal pressure (PN) Service pressure (PS) Test pressure (PT) Working Temperature Nominal Diameter (DN)

Value 200 Bar 260 Bar 390 Bar -40 0C up to +120 0C 12 mm

Temperature Design

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. The receptacle 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 receptacle. Installation procedure (a) Remove the receptacle from the box. (b) Unscrew the OD nut and remove it for panel mounting. Take care to ensure that the nut and ferrules remain undamaged. (c) Unscrew the panel mounting nut provided on the receptacle.

16

(d) Keeping the NGV profile in the front insert the receptacle into the panel hole provided 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 the help of gap inspection gauge. Always check that the filling nozzle which will be locked in with receptacle are NGV type.

Maintenance Procedure
Although the filling receptacle does not require any periodic maintenance it is good practice 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 ensure proper functioning of the receptacle. Change the O-ring like the pictures which are given below: (1)

(2)

17

TOOLS AND SPARE PARTS DATA SHEET

S.NO. DESCRIPTION PART NO. PRECAUTION Always use the WEH make original O-ring for the receptacle

O-ring

GF-50-E159S568

TROUBLE SHOOTING DATA SHEET

S.NO PROBLEM
Leakage from the end connection

CAUSE
Two ferrule end connection is not properly installed

SOLUTION
Again tighten the ferrule fitting as per the standard instruction for two ferrule fitting.

O-ring found damage condition

Dirt particles in gas or nozzle are old.

Change the O-ring as per the maintenance procedure.

18

H.P FILTER

19

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 well as 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. This gives 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 cause abrasion damage to the seats and seals of valves, the filter ensures that oil and aerosol particles dont 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

20

CONSTRUCTION
(1) Drain Plug The natural gas flows through the filter, whereas the parts like oil and other liquid aerosols generate drops, which drop to the sump of the filter, these drops are drain by the opening of drain plug. (2) O-ring The 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 in the 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.

21

(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 in the filter with a torque of 11-14 Nm.

TECHNICAL DATA SHEET

Description Pressure Nominal pressure (PN) Service pressure (PS) Test pressure (PT) Working Temperature Flow rate (KV) Value 200 Bar 260 Bar 390 Bar -40 0C up to +120 0C 0.34

Temperature

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 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 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

22

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 the help of gap inspection gauge. Check that filter is mounted properly and drain plug is present in the filter.

23

MAINTENANCE PROCEDURE
The filter requires periodic maintenance to ensure that the filter is cleaned and the element 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 Draining of oil is required after every 9000 Kms. Open the drain plug with the help of spanner and allow draining the oil. CAUTION: While opening and closing of drain plug, always hold the screw plug with spanner. After draining of oil, clean the surface with a clean cotton cloth. After draining of oil, re-tighten the drain plug with the torque of 40 N-m. CAUTION: Always change the o-ring of drain plug before re-tighten it into the filter. After tightening of drain plug always check the torque of screw plug that is 100 N-m. 2. Maintenance Procedure for filter element replacement . Filter element replacement is required after every 54000 Kms. Open the filter from the bus and fix it on bench wise. Unscrew the screw plug the proper tool as shown in the below picture.

24

 Unscrew the stay bolt and fall out the filter element as shown in the below pictures.

Remove all accessories from the screw plug and filter. Clean the screw plug as shown in the below pictures.

Place a circlip onto the screw plug with the position shown in the below picture.

25

 Place back-up o-ring and o-ring of the screw plug as shown in the below photographs:

Check the position of all accessories of screw plug as shown on the below photograph.

Insert the new filter element and tight the stay bolt as shown in the below photographs.

26

 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 be in contact with the depac grease.

3. Maintenance Procedure for Drain Plug Replacement Drain plug will only be replaced when it will be found in damage condition. Change the drain plug with the new one and tighten the new drain plug with the torque of 40 N-m. Before tightening the drain plug, always checks the condition of drain plug o-ring.

27

TOOLS AND SPARE PARTS DATA SHEET

TOOLS AND SPARE PARTS REQUIRED

WHEN REQUIRED TO GREENFUEL CHANGE PART NO. S.NO Change after every draining of oil Drain plug O- (every 17000 Kms) GF-50-E-92167 1 ring At the time of element replacement At the time of element replacement At the time of element replacement In case of damage After every 54000 Kms. At the time of element replacement

Circlip Screw plug O-ring Screw plug Back-up Oring Drain Plug Filter element Special Grease and Depac thread lubricant

GF-80-E-93858 GF-50-E322S568

PREACAUTION Use Specially designed and patented O-ring used for drain plug. Use Specially designed and patented circlip used for drain plug. Use only WEH Oring. Use only WEH Teflon ring Always use a 9/16-18 UNF drain plug. Use only WEH filter element. Dont use too much grease. 1 Bottle of each is enough for 100 vehicles

3 4 5

GF-55-E-47144 GF-69-E-9336 GF-69-E-79770 GF-E99-4 GF-Depac

28

TROUBLE SHOOTING DATA SHEET

S.NO PROBLEM
Leakage from the Inlet and outlet connection O-ring of drain plug found in damage condition If O-ring and Teflon ring of screw plug found in damage condition

CAUSE
Two ferrule end connection is not proper

SOLUTION
Screw the end connection as per the installation instruction.

Over tightening of drain plug. Insufficient lubricant (grease) provided before tightening the screw plug

Replace the O-ring with a new one. Change the rings with the new one and provide the sufficient lubricant (grease).

29

PRESSURE GAUGE

30

GENERAL DESCRIPTION
Pressure gauge is provided on the vehicle mounted on the panel and is used to indicate the 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 is dampening 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 Stainless steel.

PICTORIAL VIEW
(1) Panel Mount pressure gauge

(2) Lower mount pressure gauge

Glycerin filled pressure gauge to provide visual indication of pressure on vehicle.

Hex provided for spanner

31

TECHNICAL DATA SHEET

Description Pressure Nominal size Operating Temperature Scale ranges up to Size Value 0-400 bar 63 mm -20 0C..+60 0C +60 0C maximum

Ambient Medium

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 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 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.

Threads of pressure gauge

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.

32

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 applied on to the O-Ring of the connector.

33

f) CAUTION: Do not try to screw or unscrew by holding it on dial. It should be done 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. Screws of the gauge

O-ring of gauge Rubber seal of 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 applied on 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.

34

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
1

PROBLEM
Glycerin leakage from the pressure gauge

CAUSE
Leakage when O-ring is damage. Leakage when flange is loose in panel mount pressure gauge

SOLUTION
Change the pressure gauge. Change the pressure gauge. Tap the gauge on the dial slightly 3-4 times.

Pointer not moving initially

Movement mechanism inertia

35

APUS SOLENOID VALVE

36

GENERAL DESCRIPTION
Apus solenoid valve is an automatic valve provided at the high pressure line of the CNG system. 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 the coils. Apus solenoid valve is made up of brass material. This solenoid valve is approved by ISO 15500, A.R.A.I and E.C.E R110 for an additional safety.

PICTORIAL VIEW

Inlet Fitting Fixing Nut

Solenoid Coil

Pressure gauge Mounting (Optional)

Hex nut

1.5 Amp super sealed connector

Mounting Nut

37

CONSTRUCTION
Apus solenoid valve consists of following components. (a) Inlet filter An inlet particle filter is provided with Apus solenoid valve to protect the high pressure 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 is passed through the coil, Solenoid valve opens the path for gas to flow into the high pressure line.

TECHNICAL DATA SHEET

Description Maximum working pressure Test pressure Hydraulic collapse pressure working temperature Minimum gas flowing area Voltage Power absorption in all conditions opening P between tank and pipes at75% of nominal power (7.5W) to which it assures the opening of valve Value

PRESSURE

260 bar 330 bar > 750 bar -40 to +85 0C

TEMPERATURE SOLENOID VALVE

283 mm2 12V / 24V DC 10W (12V) 13W (24V)

360 bar

38

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 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 Apus solenoid valve when tightening it on a High pressure CNG system is given below. j. Remove the thread protection caps. k. Solenoid valve is normally closed in functioning and activates only when electric 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 the direction arrow in mind and ensuring the gas flow and direction arrow are in the same direction. Inlet of Gas Outlet of Gas

m. Male connectors with 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 provided to a torque of 50-65Nm. o. Connect the 1.5 Ampere super sealed male connector to the female connector of solenoid valve.

START-UP
After complete installation of the solenoid valve, check all the connections with the help of gap inspection gauge, direction of the solenoid valve and check the connection of the coil with 1.5 Amp super seal connector.

39

APUS SOLENOID VALVE MAINTENANCE PROCEDURE

Filter Replacement a. In the Apus Solenoid Valve the inlet particle filter must be cleaned at least every 50,000 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 Loxeal 85-21. 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. The instructions for this are: Disconnect the electrical connections. Unscrew the fixing nut on top of the coil. Remove the coil and change it. 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. a) b) c) d)

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TOOLS AND SPARE PARTS REQUIRED

TOOLS AND SPARE PARTS REQUIRED GREENFUEL PART NO.

S.NO

PREACAUTION Change the solenoid coil as per maintenance procedure. Change the filter as per the instruction given in maintenance procedure At the time of filter replacement also change the inlet fitting o-ring.

Solenoid coil (when it is damage

GF-69306771

GF-69988004

Filter

GF-FIL-8004

Inlet Fitting O-ring

TROUBLE SHOOTING DATA SHEET

S.NO PROBLEM CAUSE SOLUTION Check all the connections with the help of multi meter and if any connection is loose then connect it. Change the solenoid coil as per the instructions given in maintenance procedure.

If solenoid valve is not working

Current is not flowing in solenoid coil.

Current is flowing in solenoid coil.

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CHECK VALVE

42

GENERAL DESCRIPTION
Green fuel offers an advance, high performance no-chatter check valve (TVR1) for use with 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 Pressure Nominal pressure (PN) Service pressure (PS) Test pressure (PT) Working Temperature Value 200 Bar 260 Bar 390 Bar -40 0C up to +120 0C

Temperature

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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 with both OD end connections as well as OD x 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. Inlet of Gas Outlet 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 OD end connections the tube is inserted in the nut and tightened 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 male tapered 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.

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START-UP
After complete installation of the check valve, check all the connections and always check the direction of check flow is in the direction of gas.

TROUBLE SHOOTING
S.NO
1

PROBLEM
Leakage from the end connection.

CAUSE
Tube fitting is not tight or over tight. Teflon tape is not properly wrap. Check valve not oriented properly

SOLUTION
Check it with the gauge and tight it as per standard instructions. Change the Teflon tape as per standard instructions. Check whether direction of arrow on body is same as direction of flow of gas.

Gas is not flowing

45

PRESSURE TRANSDUCER

46

GENERAL DESCRIPTION
The pressure transducer is a device that converts mechanical signals into electrical signal to 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 the driver 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 are lit 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 must take the vehicle to the filling station to refuel the gas.

PICTORIAL VIEW

High Pressure Transducer that senses remaining pressure in CNG cylinders

TECHNICAL DATA SHEET

Description Pressure Vibration Temperature Scale ranges up to Range Operating Compensated range

Value 3.5-700 bar 20 G at 20 TO 200 Hz -40 0C to +120 0C -20 0C to +85 0C

47

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 pressure transducer 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 could impair performance of the transducer. Installation procedure This procedure applies to the mounting procedure of pressure transducer with both OD end connections as well as OD x 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 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 male tapered thread spiral, and join with a slight overlap.

t. CAUTION: Make sure tape does not overhang the first thread. The tape could shred and get into the fluid system.

START-UP
After complete installation of pressure transducer, check all the connections of check valve.

48

TROUBLE SHOOTING
S.NO
1

PROBLEM
Leakage from the end connection.

CAUSE
Tube fitting is not tight or over tight. Teflon tape is not properly wrap.

SOLUTION
Check it with the gauge and tight it as per standard instructions. Change the Teflon tape as per standard instructions. Change the transducer with the new one as per the instructions given in installation procedure.

If Transducer is not working

Damage from the external sources.

49

SPARE PART LIST

Components in Tata Xenon DESCRIPTION OF SPARE PARTS WEH make Grease WEH make Filter element SUPPLIER Part No. GREENFUEL Part No

S.NO

TML Part No. 2186 4770 0103

Qty/Pac

H.P Filter

E99-4

GF-99-E-4

E69-79770

GF-69-E-79770

25

Depac glue WEH make Oring of Drain Plug

E-99 DEPAC

GF-DEPAC

E50-92167

GF-50-E-92167

25

Circlip WEH make Filter screw plug O-ring WEH make Filter screw plug back-up O-ring Filter Screw Plug tightening tool WEH make Receptacle Oring OMB make solenoid coil of moon valve OMB make inlet filter OMB make inlet filter O-ring

E80-93858

GF-80-E-93858
GF-50-E322S568

25

E50-322S568

25

E55-47144

GF-55-E-47144

25

GF-F-50-TT-100

TN5 Filling receptacle

2896 4770 9001

E50-159S568

GF-50-E159S568

25

Solenoid Valve

2845 4761 0101

69306771 69988004

GF-69306771 GF-69988004

10

10 69306763F GF-FIL-8004 10

50

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