Universal instructions CNG Tank-sets. MODEL year 2011 SET Number. NUMMER : DATE : Copyright Prins Autogassystemen B.V VERSIE NR : DB

Transcription

1 Universal instructions CNG Tank-sets Make universal MODEL year 2011 SET Number all NUMMER : DATE :

2 TABLE OF CONTENTS... 1 Required equipment / tools / materials for installing a complete system... 2 VEHICLE CHECK... 2 POSITIONS CNG TANKS... 3 TANK-BRACKETS CNG... 4 TANK BRACKETS CNG... 5 WEDGE-PLATE, FIFTH-WHEEL FRAME PLATE AND FILLER-TUBE... 6 SPECIAL TOOLS... 7 SPECIAL TOOLS... 8 SINGLE AND DOUBLE TANK SETS... 9 BUILDING THE SET 4 TIMES Ø 340 (1) BUILDING THE SET 4 TIMES Ø 340 (2) MOUNTING OF THE TANK VALVE BUILDING THE TANK PACKAGE (1) BUILDING THE TANK PACKAGE (2) STAINLESS CNG PIPE AND CONNECTIONS INSTRUCTIONS DOUBLE FERRULE FITTINGS STAINLESS FUEL LINES EN PIPE CONNECTIONS LOCK-OFF VALVE AND CNG REGULATOR

3 PAGE 2 Required equipment / tools / materials for installing a complete system - Complete workshop toolbox ( wrenches, screwdrivers, cutters, pliers, ratchet, sockets ) - Car lift - Portable computer : operating on Windows 98,W2000 or XP. Internal memory : 16 Mb or more Memory HD space : 5MB Screen : 256 colours, advise colours 16 bits or more Com port : 1 free COM port 1 or COM port 2 with a 9 or 25 pins connector - Vehicle fuel system scan tool or OBD scan tool Prins ( part nr. 099/99928 ) - Exhaust gas analyser - Multimeter - Oscilloscope - Prins VSI diagnostic software - Prins VSI serial interface - Prins VSI break out box Torque wrench ( 10Nm ) - Portable light - Assortment drill bits 4 to 12 mm - Assortment cutters ( ø 20, 30, 50, 70 mm ) - Punching tool ø 70 mm - Round file - Portable drill or pneumatic drill - Threading device ( male M6x1, M8x1, M10x1 ) - Pipe-flaring tool ( for 6 and 8 mm copper pipe ) - Air gun - Vacuum cleaner - Hot air gun - Soldering iron, soldering tin - Wire-stripping pliers - Adhesive tape - Adhesive sealant - Thread locking compound - Anti-corrosion agent / black body coating - Gas leak detection device or foam leak spray - Shrink sleeves - Engine coolant - Locking compound part nr: 099/ Adapter tank valve (special socket) part nr : 099/992 - Bending tool 6 mm part nr: 099/ Bendingtool 12 mm part nr. 099/520001/A - Pre-assy set 6/12/caliber part nr. 199/520000/A - Mounting saddle CNG part nr. 101/090010/A - Cutting tool stainless pipe part nr. 099/520002/A VEHICLE CHECK - Before building the diesel blend system to the vehicle. - Check de driveability from the vehicle. - Check het diesel management system op fault codes. (scan tool ) Be aware of moving parts from the engine! The chassis of a truck can lower by means of air suspension! Never work on components if the system is under pressure! 2

4 PAGE 3 POSITIONS CNG TANKS Placing the CNG tanks to the truck-chassis 3

5 PAGE 4 TANK-BRACKETS CNG Trough Prins there are 3 different tank-sets CNG available: A chassis kit with 1 tank Ø 340 mm A chassis kit with 2 tanks Ø 340 mm in 1 bracket. A chassis kit with 4 tanks Ø 340 mm in 1 bracket. those kits can be mounted at both sides of the truck chassis. Also all kinds of combinations of sets in one truck-chassis are possible. An often seen combination, in smaller trucks, is the 1 times Ø 340 mm on both sides of the truck frame. The dimensions of the normal CNG tank is Ø 340 mm. For special low-deck chassis, there is a kit with 4 times Ø 280 mm available. Prins tank brackets are steel and zinc coated. Bracket 1 x Ø 340 Bracket 2 x Ø 340 4

6 PAGE 5 TANK BRACKETS CNG Bracket 4 x Ø 340 mm Cross frame Ø 340 mm On the tank frame 4 x Ø 340 first the two bottom tanks are placed. Then the cross frame is placed on the bottom tanks and the two top tanks can be mounted. Check that all facings against the tanks are sealed with the rubber strip. For all bolt-connections a bolt quality off at least 8.8. steel is required bolts need to be mounted with steel rings and self-locking nuts We advise to use standard bolts and torque them to standard torque loads (M12 and M14) For tank bracket 1 x 340 use 4 times a M12 bolt 8.8 For tank bracket 2 x 340 use 6 times a M12 bolt 8.8 For tank bracket 4 x 340 use 6 times a M14 bolt 8.8 On the angled part of the truck chassis the bracket needs to be mounted with a wedge-plate The wedge-plates are available through Prins. On the straight part of the truck chassis the brackets can be mounted directly to the truck-frame. Never position the filler tubes directly to the truck main frame! Use always a fifth wheel plate between the filler tubes and the vehicle mainframe! 5

7 PAGE 6 WEDGE-PLATE, FIFTH-WHEEL FRAME PLATE AND FILLER-TUBE Fifth-wheel frame plate (MAN) Prins part-nr. 001/560023/A Wedge-plate 4.5 angle (MAN) Prins part nr. 001/560024/A Filler-tube part nr. 001/500253/A 6

8 PAGE 7 SPECIAL TOOLS Pre-assembly tools for Double Ferrule 6 mm and 12 mm Bending tool 12 mm Cutting tool for stainless pipe. 7

9 PAGE 8 SPECIAL TOOLS To mount the tank valve in the CNG tank, Prins offers several special tools, which are necessary to be used in building CNG chassis sets. The special tank valve-socked is a must for correct mounting of the tank valve. Also the mounting saddle must be used to work on the tank without damaging the tank paint. The tank valve should always be torqued to Nm. Mounting saddle CNG tank valve. Special Socked CNG tankvalve. The CNG tank strapped in the mounting saddle. Bending-tool for 6 mm stainless CNG pipe. 8

10 PAGE 9 SINGLE AND DOUBLE TANK SETS 1 x Ø 340 en 2 x Ø 340 The most simple tank set CNG is the 1 times Ø 340 mm. In this tank situation, the two brackets are directly mounted to the trucks mainframe. The CNG tanks are available from 69 litre up to 140 litre volume. The length of the tanks is from 960 mm up to 1850 mm. Tank situation with 1 x Ø 340 mm with 140 litre volume Situation as build for 2 x Ø 340 mm direct to the mainframe. 9

11 PAGE 10 BUILDING THE SET 4 TIMES Ø 340 (1) With the sets of 4 times Ø 340 Prins offers two different packages. The main difference is if the set is mounted on two or on three brackets. packages up to 1330 mm length (100 litre) can be mounted on two brackets. The tanks with a length of 1580 mm (120 litre) and a length of1850 mm (140 litre) should be mounted on 3 brackets. brackets for the 4 times tank sets are the same. For all situations as shown, Prins has calculations for the brackets available. The filler tube is available through Prins in a zinc-coated quality with a length of 500 mm The filler tube has to be cut to the required length is your chassis situation. 10

12 PAGE 11 BUILDING THE SET 4 TIMES Ø 340 (2) In the situation shown in this picture the front bracket is mounted on the angled part of the trucks mainframe. To get the bracket in a 90 degree angle to the truck mainframe it is a must to put a wedge between the tank bracket and the chassis. The second bracket also needs a wedge to get it 90 degrees to the truck centre line. The second and third bracket also need 6 filler tubes to get all three brackets in line with each other. The third bracket is mounted to the straight part of the mainframe, so it does not need a wedge but a filler plate fifth wheel frame and 6 filler tubes to line up the bracket. Measure the length of the filler bushings with a long straight steel bar from the first bracket to the third one. Cut the filler tubes exact to its required length and make sure the cuts are 90 degrees. Never put the filler tubes direct to the mainframe. Always use a plate in between tubes and chassis. Determine where the boltholes should go and drill 14.5 mm to take the M14 bolt. ( 6 per bracket) Determine the bolt length and mount them with steel rings and self-locking nuts. Torque the bolts to the suppliers specs. 11

13 PAGE 12 MOUNTING OF THE TANK VALVE Place the rubber strip in the mountingsadle and put the tank in. Strap the tank solid to the frame (rubber under the straps). Now it is possible to turn the tankvalve in without damage the tank. Clean threat of valve and inside the tank. Only use Prins locking compound on the valves thread aswell on the tanks threaded hole. Torque the valve with the special socked to a load of 250/300 Nm. 12

14 PAGE 13 BUILDING THE TANK PACKAGE (1) First place the rubber strips in the brackets and spray the upper-side with silicone, this is necessary to turn and slide the tanks in the correct position in the bracket. Check if the tanks are correctly in their bed and the rubber strip is positioned correctly to the tank frame. Put the protective rubber on the facings from the cross frame and place the frame on the bottom two tanks. ( facing plate outside) Again spray the rubber with silicone. Place the top two tanks in the frames and check the positions of the valves to be horizontal. It is possible to find a length difference in tanks with the same volume. Make sure that the tanks are in line at the valve side of the tank and check the valves to be horizontal. 13

15 PAGE 14 BUILDING THE TANK PACKAGE (2) The tank package is held together with a stainless steel strap. The stainless strap should be mounted with the polished side up. The closed wrap is on the chassis-side of the bracket. The open wrap is on bottom side and will holds the clamping set. A flange-pin is used in the top of the bracket and locked with a split pin. The bracket-pin with the M 12 thread is mounted in the bottom hole of the bracket and locked with 2 split pins. The strap-pin is placed in the open wrap of the Strap Put the Rubber strip under the stainless strap. Use the 10 mm bolt and nut to tighten the tank package. If the tank package is tightened remove the M10 bolt and mount the M12 en Key bolt. Supplied are M12 bolts in length of 100 and 90 mm. Check per bracket witch length bolt is to be used. Re-tighten the M12 bolts after filling the tanks and test drive. 14

16 PAGE 15 STAINLESS CNG PIPE AND CONNECTIONS In a normal tank situation the tanks are connected as shown in this picture. First bent the stainless pipe in the required model and then cut it to length. Be sure that all the stainless pipes are mounted without material-stress. Connect all 4 tanks and plug the not used valve port in tank number 4. Connect the wiring loom to the tank valves and strap the harness to the stainless pipe. The stainless piping between the tanks is fillerline and consumption-line in one. Connect the left and right filler head to the tank fuel-line by the use of T connectors. Connect the fuel-line to the pressure-regulator with another T-connector. Fasten the stainless fuel-line solid to the truck frame and body each 40 cm. In case of a set with fast fill NGV 1 HF and NGV 2 filler heads the tank connections are different. In this case the tanks are connected parallel. From the filler head we start building with 12 mm stainless pipe. The 12 mm T-connectors are reduced to 6 mm And 6 mm pipes will run to the tanks. The 12 x 1.5 stainless pipe can be bent also, with a 12 mm bending tool. Plug the not used ports of the tank valve. en Key plugs M12x1 are in the set. the connections are of the double ferrule type. Read the instructions below!! 15

17 PAGE 16 INSTRUCTIONS DOUBLE FERRULE FITTINGS 16

18 PAGE 17 STAINLESS FUEL LINES EN PIPE CONNECTIONS Mount the two filler bracket to the truck frame on the right and left side. Mount the standard filler heads in the brackets. Bent the stainless 6 mm pipe en connect those to the filler heads. Check that the fuel lines are not close to hot Components of the truck. Each 40 centimetre the fuel line should be fixed to the bodywork of the truck. In the picture an example of a how parts can be built together. In case of the high flow filler heads the advice is to build the filler heads as close to the tanks as possible. Stainless filler head brackets in a long and short model are available through Prins Stainless 6 mm pipe is available in 4 metre lengths. Make as less bents as possible and use the T- connectors which are in the set. Place the fuel lines so that repair and maintenance can be done without disassembly of the diesel blend system. Check during fuelling and after test run for Leakage!! 17

19 PAGE 18 LOCK-OFF VALVE AND CNG REGULATOR Run a 6 mm stainless gas line from the tank package to the Apus lock-off valve. The manometer on the Lock off valve holds the pressure sensor for tank content. After ignition is switched on and a pre-opening has taken place the tank content is visible on the manometer From the lock-off run a 6 mm line to the CNG regulator. Behind the input side insert off the lock off valve a gas filter is placed. The input side insert of the CNG regulator is a gas filter. Both filters can and should be changed at service intervals. Spray the top off the regulator with anti-corrosion agent to conserve against rust. 18

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