Stralis Cng (compressed Natural Gas)

Transcript

STRALIS CNG (COMPRESSED NATURAL GAS) SUPPLEMENT TO BODYBUILDER H E A V Y R A N G E INSTRUCTIONS EDITION 2010 Publication Edited by: IVECO S.p.A. Technical Application Strada delle Cascinette, 424/34 10156 Torino (TO) - Italy www.iveco.com Printed 603.95.081 - 1st ed. 02/2010 Publication produced for IVECO by SATIZ TECHNICAL PUBLISHING c/o Iveco - Customer Service Lungo Stura Lazio, 15 10156 Torino - Italy STRALIS CNG Bodybuilders instructions Printed 603.95.081 - 1st ed. Base - 02/2010 UPDATE DATA Section Description Page Revision date Update data Printed 603.95.081 Base - 02/2010 Update data Base - 02/2010 Printed 603.95.081 Foreword 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 make sure that all the accident-prevention equipment such as, for instance, goggles, helmet, gloves, boots, etc. as well as the working, lifting and handling equipment are available and in good working order. Finally, make sure that you operate on the vehicle in such conditions as 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 that the 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 the latter 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 dealt with in this publication. After every single intervention, the functioning, efficiency and safety conditions established by IVECO shall be restored. Contact the IVECO 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, for technical 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 Manager for your market before carrying out any operations. Symbols - Warnings Danger for persons Missing or incomplete observance of these prescriptions can cause serious danger for persons’ safety. Danger of serious damage for the vehicle Partial or complete non observance of these prescriptions can cause serious damages to the vehicle and sometimes guarantee lapse too. General danger ! It includes the dangers of above described signals. Environment protection It indicates correct behaviour in order that vehicle use is environmentally friendly as much as possible. NOTE It indicates an additional explanation for a piece of information. Foreword Printed 603.95.081 Base - 02/2010 Page header and footer interpretation Vehicle type Print number Section title Chapter title Section number page number Basic edition month year Foreword Base - 02/2010 Printed 603.95.081 INDEX OF SECTION Section Guidelines and specifications 1 PTO management 2 NOTE 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. Index of section Printed 603.95.081 Base - 02/2010 Index of section Base - 02/2010 Printed 603.95.081 STRALIS CNG Guidelines and specifications 1-1 Index SECTION 1 Guidelines and specifications Page Index Printed 603.95.081 Base - 02/2010 1-2 Guidelines and specifications STRALIS CNG 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 Index Base - 02/2010 Printed 603.95.081 STRALIS CNG Guidelines and specifications 1-3 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 present perceptible 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 the special 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 during its execution. ! NOTE The highly flammable nature of the compressed gas does not allow the vehicles to be fitted out or converted for fire fighting purposes or for use in potentially critical environments (for example: airports, refineries, etc.) IVECO designs, homologates and builds CNG vehicles in compliance with Regulation ECE 110 currently in force. Operations to the engine fuel system that involve different components to those homologated by IVECO (even if they have been homolgated by an Independent Technical Unit) involve the vehicle having 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 adding canisters, the type of canister fastening) should be subject to approval by IVECO. General Information Printed 603.95.081 Base - 02/2010 1-4 Guidelines and specifications STRALIS CNG 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. Wear protective 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 be extracted from the switch. • Keep fire extinguishers of suitable class (class A, B, C) with other fire extinguishing devices at hand. Class C fire extinguishers are 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 the rules 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. Safety Rules Base - 02/2010 Printed 603.95.081 STRALIS CNG Guidelines and specifications 1-5 Operations on the system 1.3 Operations on the system 1.3.1 Main components Tank The 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 116875 1. Tank - 2.. VBE safety and shutoff valves VBE safety and shutoff valves A 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 pressurizing should 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 the canisters (for example, if one of the pipes breaks). • Fuse pad which, in the case of a fire, melts at 103 ± 10 ºC and allows the escape of gas outwards, directly and securely, preventing the canister from exploding. Operations on the system Printed 603.95.081 Base - 02/2010 1-6 Guidelines and specifications STRALIS CNG The valves are the VBE type, with a tapered attachment thread and they are designed for 70 litre, 80 litre and 140 litre steel canisters, respectively. NOTE The valves are not interchangeable. NOTE If one of the flow limiting valves or solenoid valves is not working, this may be deceptive as far as the effective pressurizing status of the canisters is concerned. With this in mind, consult the solenoid valve checking and replacement procedures in paragraphs 1.3.3 and 1.3.4. 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 fitted between the mount and the pipe; this must be in good condition at all times to prevent metal/metal contact. ! For safety reasons, both during fitting out and maintenance, the use of gas pipes as fastenings for other pipes IS PROHIBITED. In special cases, where space is limited, the electrical cables only can be fastened to the gas pipes (using PVC 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 that they have no scratches, grooves, cuts or distortions, visible to the naked eye. If necessary, the pipes should be suitably protected. Operations on the system Base - 02/2010 Printed 603.95.081 STRALIS CNG Guidelines and specifications 1-7 Figure 1.2 87386 CONNECTIONS WITH NOSE Figure 1.3 87387 CONNECTIONS WITH TWIN SEAL Operations on the system Printed 603.95.081 Base - 02/2010 1-8 Guidelines and specifications 1.3.2 NOTE STRALIS CNG General requirements Any change to the system layout will definitely entail re-homologation of the vehicle. 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 all the 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 this purpose, 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 original installation sequence. ! After replacement of the valves or after any operation to the high pressure section of the system, the IVECO SERVICE DEPARTMENT should carry out a LEAKAGE TEST (at 300 bar) and, following a positive result, they can issue a test certificate. Operations on the system Base - 02/2010 Printed 603.95.081 STRALIS CNG 1.3.3 ! Guidelines and specifications 1-9 Emptying the gas system Before performing significant operations (such as welding) or servicing the engine, the gas circuit must be 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 engine must 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 are no sources of possible flames within a radius of at least 5 metres surrounding the vehicle. Operations on the system Printed 603.95.081 Base - 02/2010 1-10 Guidelines and specifications STRALIS CNG Partial emptying procedure Figure 1.4 116876 ! This operation only guarantees the ventilation of the system downstream of the canisters. Therefore it is vital to make sure that no work is carried out within a distance of 5 metres of the canisters, that could produce sparks (welding, cutting, grinding, drilling) or that involves the use of equipment with an electrical power supply or that uses naked flames. 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 free end 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 all suitable precautions; • check that pressure gauge (4) is reading zero circuit pressure. 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, remove the 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. Operations on the system Base - 02/2010 Printed 603.95.081 STRALIS CNG Guidelines and specifications 1-11 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). Remove the 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 ring nut (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). Operations on the system Printed 603.95.081 Base - 02/2010 1-12 Guidelines and specifications STRALIS CNG 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 the pin (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 them if 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 either carefully put aside or replaced) as shown in the following paragraph. Operations on the system Base - 02/2010 Printed 603.95.081 STRALIS CNG Guidelines and specifications 1-13 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 carrier sleeve. • 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. Operations on the system Printed 603.95.081 Base - 02/2010 1-14 Guidelines and specifications STRALIS CNG Figure 1.11 117663 • Check that coil (4) does not present signs of damage. If necessary, perform the checks described in the chapter ”VBE valve functional 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 NOTE ! 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 have been removed. Before disconnecting the solenoid valves, the system must be completely drained following the procedure described in the “Draining the gas system” chapter. Figure 1.12 116878 • Remove the screws (1) and remove the cover (2). Operations on the system Base - 02/2010 Printed 603.95.081 STRALIS CNG Guidelines and specifications 1-15 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 electrical connection (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 percussion pneumatic 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. NOTE In this operation, make sure that tool 99355018 (2), does not damage the VBE valve thermal fuse device. Operations on the system Printed 603.95.081 Base - 02/2010 1-16 Guidelines and specifications 1.3.5 STRALIS CNG 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 noses from 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 connectors If 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 supplied assembled 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 check the 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 pack and 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 pipe with the union. • Tighten the union s nut down by hand until the two cones are packed together. Mark the position of the nut relative to the union body. • Use two wrenches working in opposite directions to tighten the nut down half a turn. This wedges the second cone under the 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. Operations on the system Base - 02/2010 Printed 603.95.081 STRALIS CNG 1.3.6 Guidelines and specifications 1-17 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. They must therefore be replaced during every refitting. • New minor components must be systematically restored to their original positions in accordance with the original installation sequence. B) Repainting of outfitted frames The 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 kept sufficiently far away from the control unit to avoid problems of induced overheating. This distance must never be less than 50 mm. Operations on the system Printed 603.95.081 Base - 02/2010 1-18 Guidelines and specifications STRALIS CNG Cylinders 1.4 Cylinders Figure 1.16 116886 The methane (CNG) is stored in compressed form at a pressure of 200 bar in a certain number of cylinders positioned in the chassis and 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 check valve is inserted in the solenoid valve fitted on the first cylinder and connected to the refuelling filler. The check valves are used to prevent the release of gas into the outside environment when the valve is extracted after the refuelling operation. NOTE A faulty flow valve or solenoid valve may lead to incorrect indications regarding the cylinder contents. Refer to the solenoid valve inspection and replacement procedures in the corresponding paragraph 1.3.4. Important information concerning the cylinders is punched into their upper surface (o). CNG ONLY - DO NOT USE AFTER FABER 01/1234/123 KG L (3) (1) (4) (2) 15°C/ (5) (6) MPaE 110R(7) (8) CNG-I (9) USE TESTED FABER CYLINDERS ONLY (10) 01/1234/ 123 = FABER serial numbers (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 Cylinders Base - 02/2010 Printed 603.95.081 STRALIS CNG 1.4.1 Guidelines and specifications 1-19 Cylinder scheduled overhauling according to ECE/ONU R 110 standards Methane gas cylinders for road vehicles must be inspected EVERY FOUR YEARS by competent authorities responsible for certifying their 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 manufacturer unless the competent authorities decide otherwise. A cylinder that has not suffered any damage following the collision impact can 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 or scrapped and removed from service. Cylinders Printed 603.95.081 Base - 02/2010 1-20 Guidelines and specifications 1.4.2 STRALIS CNG Cylinder replacement Removal ! Before disconnecting the cylinders, empty the system completely following the procedure described in the ”Methane system emptying” chapter. Figure 1.17 143782 • 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 are in 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, replace the 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. Cylinders Base - 02/2010 Printed 603.95.081 STRALIS CNG 1-21 Guidelines and specifications 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 1 Terminal 15 for air conditioning / Heated prefilter / Radio 24V Food warmer + Fridge / BM (Bed Module) / Diagnosis connector / OBD 2 connector 3 Tachograph / IC / Centralized locking (remote control) 4 SWI (Steering Wheel Interface) 5 Cigar lighter - 24 V/12 V voltage reducer / Radio 24 V 6 Tilted cab / Drier / Water presence in fuel filter / ”Shut off” solenoid valve/ Projectors positioning Red color fuse holder (70602) Ref. Function 1 ACC (Adaptive Cruise Control) / Allison gearbox 2 Eurotronic II / Fan electromagnet coupling / Allison gearbox 3 Internal lighting / Tool compartment lights 4 EBS / ABS - D BASIC 5 EBS 6 EBS / ABS - D BASIC Natural color fuse holder (70603) Ref. Function 1 Driver’s door module (DDM) / driver’s electric window without DDM/PDM Passenger door module (PDM) / passenger’s electric window without 2 DDM/PDM 3 IC (Instrument Cluster) 4 CNG (Methane fuel system power supply) 5 Body Computer 6 Body Computer Delivery (A) 5 Terminal +15 10 +Batt 5 5 20 10 +Batt +30 +30 +15 Delivery (A) 10 10 5 5 15 15 Terminal +15 +30 +30 +15 +30 +30 Delivery (A) 20/15 Terminal +30/+15 20/15 +30/+15 10 30 25 25 +15 +30 +30 +30 Relays / Fuse holder control unitRelays / Fuse holder control unit Printed 603.95.081 Base - 02/2010 1-22 Guidelines and specifications STRALIS CNG Figure 1.19 126166 Black color fuse holder (70604) Ref. 1 2 3 4 5 6 Function EM (Expansion Module) Air-conditioning system Air-conditioning system / IT / Navigation Auxiliary heating Auxiliary heating VCM (Vehicle Control Module) Delivery (A) 15 15 5 15 5 20 Terminal +30 +30 +30 +30 +30 +30 Delivery (A) 15 5 7.5 10 15 7.5 Terminal +30 +15 +30 +30 +15 +15 Natural color fuse holder (70605) Ref. 1 2 3 4 5 6 Function EM (Expansion Module) Vehicle levelling Chassis level adjustment Decelerator with CAN / Headlight washer Decelerator with CAN / Retarder / Mirror heating Heated seat / Central lubrication / IT / navigation / Centralized locking Relays / Fuse holder control unitRelays / Fuse holder control unit Base - 02/2010 Printed 603.95.081 STRALIS CNG Guidelines and specifications 1-23 Figure 1.20 126166 Black color fuse holder (70401) Ref. 1 Cab tilting 2 Cab tilting 3 Body builders 4 Heated windscreen Function Black color fuse holder (70402) Ref. Function 1 Heated windscreen 12 V internal lighting / 12 V Reading lights / Navigation system / Telematic 2 system 3 4 K15 for alternator Black color fuse holder (70403) Ref. Function 1 EM 2 EM 3 EM / ACC 4 CNG (12V power supply for MF3 control unit and flow meter) Delivery (A) 25 5 10 25 Terminal +30 +30 +30 +30 Delivery (A) 25 Terminal +30 5 - 5 +15 Delivery (A) 10 10 5 5 Terminal +30 +30 +15 + Delivery (A) 10 7,5 5 20 Terminal +15 +15 +30 +30 Delivery (A) 5 5 15 Terminal +15 +15 +15 10 +15 Black color fuse holder (70404) Ref. 1 2 3 4 Function Trailer ABS/EBS Sunblind CNG (Power supply for MF3 control unit) CNG (Supply for solenoid valves for canisters) Black color fuse holder (70405) Ref. Function 1 CNG power supply of spark plugs 2 CNG power supply of spark plugs 3 CNG (Power supply for MF3 control unit) CNG (Supply for Lambda sensors, waste gate solenoid valve and pressure 4 regulator solenoid valve) Relays / Fuse holder control unitRelays / Fuse holder control unit Printed 603.95.081 Base - 02/2010 1-24 Guidelines and specifications 1.5.2 STRALIS CNG Supplementary remote switches Figure 1.21 126166 Ref. A B C D E F G H I K L M N O P R S Description Fan electromagnet coupling relay Water heater remote control switch Allison gearbox remote-control switch AT/AD Manual air conditioner remote-control switch Water heater remote-control switch Allison gearbox remote-control switch AT/AD Manual air conditioning remote-control switch (CNG) Diodes for cab tilting Manual air conditioning remote-control switch Manual air conditioning remote-control switch Remote control switch for IGC Manual air conditioning remote-control switch Manual air conditioning remote-control switch Engine disengagement relay (CNG) Manual air conditioning remote-control switch Manual air conditioning remote-control switch Remote control switch 12 V terminal 15 (CNG) Component code 25737 25337 25210 25332 25325 25609 25752A 61000B 25874 25310 25903 25322 25332B 25752B 25327 25332A 25751 Relays / Fuse holder control unitRelays / Fuse holder control unit Base - 02/2010 Printed 603.95.081 STRALIS CNG 1-25 Guidelines and specifications Remote-control switches a) Positioned behind the BODY COMPUTER. Figure 1.22 73672 Ref. GA GB GC GD GE GF GG Component code Description Gas cylinder solenoid valve remote control switch (CNG) 40A Remote-control switch (terminal 15), 50A Starting remote-control switch (50), 40A Remote control switch for supply (CNG) 40A Cabin tilting remote-control switch Cabin tilting remote-control switch Cabin tilting remote-control switch 25921 25213 25200 25918 25906 25722 25723 b) Positioned in the control unit compartment. Figure 1.23 113554 Ref. BA BB BC BD Description Headlight washer enablement relay - Component code 25740 - Relays / Fuse holder control unitRelays / Fuse holder control unit Printed 603.95.081 Base - 02/2010 1-26 Guidelines and specifications STRALIS CNG Relays / Fuse holder control unitRelays / Fuse holder control unit Base - 02/2010 Printed 603.95.081 STRALIS CNG PTO management 2-1 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 Index Printed 603.95.081 Base - 02/2010 2-2 PTO management STRALIS CNG Index Base - 02/2010 Printed 603.95.081 STRALIS CNG PTO management 2-3 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 fuel injection quantity like in a Diesel engine, but by air flow through the engine. The reaction times are therefore slightly delayed compared to a Diesel engine. This reduces rpm control quality in response to varying load. NOTE This Bodybuilder Instructions appendix was made to explain the precautions to be taken and the limitations to be respected when installing a Power Take-off (PTO) on a CNG engine. Introduction Printed 603.95.081 Base - 02/2010 2-4 PTO management STRALIS CNG Mechanical Power Take---Off (PTO) installation, maximum power take---off 2.2 Mechanical Power Take-Off (PTO) installation, maximum power take-off Any type of mechanical PTO installation known for Diesel 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 need of torque variation. Figure 2.24 max torque 200 kW engine output torque (Nm) PTO max torque engine speed [rpm] 142794 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 installed PTO has a transmission ratio (which is virtually always the case), the torque @PTO can be calculated multiplying the values mentioned here by the transmission ratio, the rotational speed @PTO may be calculated by dividing the output values by the transmission ratio. Mechanical Power Take-Off (PTO) installation, maximum power take-off Base - 02/2010 Printed 603.95.081 STRALIS CNG 2.2.2 PTO management 2-5 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 Nm per 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 speed oscillations with amplitude greater than +/- 50 rpm and engine speed accelerations greater than +/- 100 rpm/s. Figure 2.25 rpm/s engine speed [rpm] rpm 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 can occur. IVECO can not be held liable for any damage caused by inadequate PTO torque/power consumption in “full power PTO operation - blue zone”. Mechanical Power Take-Off (PTO) installation, maximum power take-off Printed 603.95.081 Base - 02/2010 2-6 PTO management 2.2.4 STRALIS CNG 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 700 rpm 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 order to avoid engine stall. The body must not raise PTO torque quicker than 50 Nm per second. Mechanical Power Take-Off (PTO) installation, maximum power take-off Base - 02/2010 Printed 603.95.081 STRALIS CNG PTO management 2-7 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 Bodybuilder 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 PTO mode 0 (driving mode), there is no difference to Diesel engines, chapter “4.6.3.1 RPM 0 mode (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 not treated 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. Electronic PTO setup Printed 603.95.081 Base - 02/2010 2-8 PTO management STRALIS CNG Table 1 English description in EASY tool setting instruction Engine speed increase/decrease via depends on application - use setSET+/SETtings like for Diesel engine Time to reach the selected engine revs 0,1 sec Disabling speed for external engine depends on application - use setrequest tings like for Diesel engine Disabling PTO mode during the depends on application - use setchange of CC management external/tings like for Diesel engine internal or internal/external Temporary engine speed increase on OFF expansion module request Max. Revs (high idle) that can be reached by engine in case of CAN not used kickdown Temporary engine speed increase on OFF driver request by expansion module Max. Revs (high idle) that can be reached by the engine in case of not used Driver’s kickdown Engine idle shut-off requested by depends on application - use setexpansion module according to the tings like for Diesel engine speed Speed for P.T.O. disabling depends on application - use settings like for Diesel engine Re-activation speed depends on application - use settings 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. Electronic PTO setup Base - 02/2010 Printed 603.95.081 STRALIS CNG PTO management 2-9 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 Enable for maximum engine speed that can be set by accelerator pedal real meaning of parameter standard settings Setting instruction Normal PTO operation PTO during driving green zone yellow zone Full power PTO operation blue zone OFF high engine speed limit 1150...2300 rpm Maximum engine speed that can be set by accelerator (applied always in this PTO 250 rpm (or more) higher than mode) engine speed control target pedal value low engine speed limit Minimum speed that can be set by set - (WARNING: (applied always in this PTO 700 rpm do not exceed 150 rpm of Idle Engine Speed) mode) do not modify Maximum Torque (default 2500 Nm) high engine speed limit 1150...2300 rpm (applied always in this PTO 250 rpm (or more) higher than Maximum engine speed that can be set by SET+ mode) engine speed control target value high engine speed controlcuve slope 0 ler feedback factor depends on application - use Speed Threshold for PTO/Cruise Control Activation settings like for Diesel engine depends on application - use PTO Shut-Off when Parking brake is OFF settings like for Diesel engine Activation of the parameter for the maximal PTO depends on application - use Speed settings like for Diesel engine depends on application - use Maximum PTO Speed settings like for Diesel engine depends on application - use PTO Shut-Off by pressing the brake pedal settings like for Diesel engine depends on application - use PTO Shut-Off via engine brake request by the driver settings like for Diesel engine depends on application - use PTO Shut-Off via Intarder by the driver settings like for Diesel engine depends on application - use PTO Shut-Off via CAN engine brake request settings like for Diesel engine depends on application - use PTO Shut-Off via CAN Intarder request settings like for Diesel engine depends on application - use PTO Shut-Off by pressed clutch pedal settings like for Diesel engine PTO Shut-Off when revs are lower than minimum OFF speed hat can be set by SET PTO Shut-Off when revs are higher than maximum OFF speed that can be set by SET + depends on application - use PTO Shut-Off in case of error on Cruise Control Module settings like for Diesel engine depends on application - use Check on fault of switches for service and parking brake settings like for Diesel engine OFF 1800...2300 rpm 700...800 rpm do not modify (default 2500 Nm) 1800...2300 rpm 0 15 km/h ON ON 2 km/h ON ON ON ON ON ON OFF OFF ON ON Electronic PTO setup Printed 603.95.081 Base - 02/2010 2-10 PTO management STRALIS CNG 22222. real meaning of parameter Standard settings accelerator pedal deactivaAccelerator Pedal Disabling tion during this PTO mode engine speed control automatically engages when Resume Function at Starting engine is switched on engine speed control autoKeeping the Resume Function by other PTO modes matically engages when switching to this PTO mode PTO Shut-Off in case of error on vehicle speed sensor english description in EASY tool PTO Shut-Off by external request Shut-off conditions in case of error on vehicle speed sensor PTO Shut-Off via coolant temperature control Coolant Temperature PTO Shut-Off with engaged gear PTO Shut-Off with engaged reversing gear Activation of the control on the lowest gear to engage/shut off the PTO Lowest gear to engage/shut off the PTO Activation of the control on the highest gear to engage/shut off the PTO Highest gear to engage/shut off the PTO PTO mode disabling via OFF key of the cruise module Cruise Control and MEMO Function Management Engine Speed Range via MEMO Maximum Speed via SET+ Temporary Engine Speed Increase by other ECU Temporary Engine Speed Increase by driver request Replace Speed Enable Replace Speed Value ISC Parameter Set indication Torque Limitation depending upon engine revs (REVS) Torque Limitation depending upon engine revs (TORQUE) setting instruction Normal PTO operation PTO during driving green zone yellow zone Full power PTO operation blue zone ON (accelerator pedal deactivated) OFF (accelerator pedal active) depends on application - use setOFF tings like for Diesel engine depends on application - use setOFF tings like for Diesel engine ON depends on application - use settings like for Diesel engine depends on application - use settings like for Diesel engine OFF Not used ON ON depends on application - use settings like for Diesel engine depends on application - use settings like for Diesel engine depends on application - use settings like for Diesel engine depends on application - use settings like for Diesel engine depends on application - use settings like for Diesel engine enginespeedcontroladjustment possibilities for the driSet to “without calibration” ver (via cruise control buttons) 900...1300 rpm (green zone) engine speed control target 1000...1300 rpm (blue zone) value 250 rpm (or more) lower than high engine speed limit vehicle speed limit to switch 2 km/h off engine speed control EuroTronic can override OFF engine peed limit Accelerator pedal kickdown can override engine speed OFF limit Customized settings Use a special vehicle speed depends on application - use setlimit in this PTO mode tings like for Diesel engine ON ON ON OFF Not used ON Not used Not used Not used Not used Not used ON Set to “without calibration” Not used 2 km/h OFF OFF depends on application use settings like for Diesel engine Vehicle speed limit value for depends on application depends on application - use setthis PTO mode use settings like for Diesel tings like for Diesel engine engine do not modify do not modify (default 7) (default 7) do not modify (default 2500 Nm at any engine speed) do not modify (default 2500 Nm at any engine speed) Electronic PTO setup Base - 02/2010 Printed 603.95.081