EUROCARGO CNG
(COMPRESSED
NATURAL GAS)
SUPPLEMENT TO BODYBUILDER
M
E
D
I
U
M
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A
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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 603.95.141 - 1st ed. 11/2010
Publication produced for IVECO by
SATIZ TECHNICAL PUBLISHING
c/o Iveco - Customer Service
Lungo Stura Lazio, 15
10156 Torino - Italy
EUROCARGO CNG
Supplement to Bodybuilders instructions
Printed 603.95.141 - 1st ed.
Base - 11/2010
UPDATE DATA
Section
Paragraph
Description
Revision date
Update data
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Update data
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Printed 603.95.141
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
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Page header and footer interpretation
Vehicle type
Print
number
Section title
Chapter title
Section number page number
Basic edition month year
Foreword
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Printed 603.95.141
INDEX OF SECTION
Section
Guidelines and specifications
1
PTO management
2
NOTE This document supplements, but does not replace the 2009 version of the:
”EUROCARGO BODYBUILDERS INSTRUCTIONS”.
Each subject not explicity dealt with should be referred them.
Index of section
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Index of section
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EUROCARGO CNG
Guidelines and specifications
1-1
Index
SECTION 1
Guidelines and specifications
Page
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
1.3.3.1
Partial emptying procedure
1-10
1.3.3.2
Total drainage
1-11
1.3.4
VBE solenoid valve replacement
1-15
1.3.5
Repairs on pipes and unions
1-17
1.3.6
Special requirements
1-18
1.4
Cylinders
1-19
1.4.1
Cylinder scheduled overhauling according to ECE/ONU R 110 standards
1-20
1.4.2
Cylinder replacement
1-21
1.5
Relays / Fuse holder control unit (IBC3)
1-22
1.5.1
Fuse
1-22
1.5.2
Minirelay set (black)
1-25
1.5.3
Microrelay set (yellow)
1-26
1.5.4
Supplementary fuses
1-27
Index
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Guidelines and specifications
EUROCARGO CNG
Index
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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 Eurocargo 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
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1-4
Guidelines and specifications
EUROCARGO 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
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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
149724
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.
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Guidelines and specifications
EUROCARGO 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
A manual cock (cut-off valve) is present upstream of the system to prevent gas entering when the engine is off .This cock must be
closed before any maintenance operation on the components upstream (e.g.: pressure reducing valve, 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 twing seal (Figure 1.2, page 1-7).
Pipes connecting manifold to VBE cylinder valves
• Pipes of external diameter 10 mm.
• Fittings with nose (Figure 1.3, page 1-7).
Pipes connecting VBE safety valves
• Pipes of external diameter 6 mm.
• Fittings with nose (Figure 1.3, page 1-7).
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.
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Guidelines and specifications
1-7
Figure 1.2
87386
CONNECTIONS WITH NOSE
Figure 1.3
87387
CONNECTIONS WITH TWIN SEAL
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Guidelines and specifications
1.3.2
NOTE
EUROCARGO 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 replacing a valve or after any operation on the high pressure section of the system, a
HYDRAULIC SEAL TEST must be carried out at 300 bar.
This test must be carried out by IVECO Aftersales Service, which will issue an inspection certificate
if the vehicle passes.
Operations on the system
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EUROCARGO CNG
1.3.3
!
Guidelines and specifications
1-9
Emptying the gas system
Before important operations on the vehicle (e.g.: welding operations) or maintenance operations on
the engine, the gas system must be flushed with air.
Draining of the pipes alone is usually sufficient. In some cases, however ,it could be necessary to drain the entire system (including
cylinders).
The decision depends on the importance and type of operation to be carried out but if uncertain, always opt for the safest solution,
i.e. draining down the full system.
If there are no problems with the system (e.g.: leaks) it is preferable to let the gas run out by leaving the engine running. If pressure
in the system is lower than 20 bar, correct fuel metering can no longer be guaranteed.
The engine must only be run at idle speed to prevent damage to the catalytic converter.
!
The drainage manoeuvres must be carried out with the engine off and in the open in an area without
any spark sources within a radius of at least 5 metres around the vehicle.
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Guidelines and specifications
EUROCARGO CNG
1.3.3.1 Partial emptying procedure
Figure 1.4
138255
!
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;
• ground the vehicle;
• check that the cocks (1) on all cylinders are closed;
• connect a rubber pipe (compatible with methane) to vent valve outlet (4) to dissipate the gas, the free end of the pipe must
be at least 5 m from any potential spark source;
• slowly open the ventilation valve (3) taking care to avoid rapid decompression, which could cause local freezing;
• check that pressure gauge (2) is reading zero circuit pressure.
NOTE
If there is a second group of canisters, the previous operations should be repeated on it.
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Guidelines and specifications
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1.3.3.2 Total drainage
After partial draining, total draining of the system also requires ventilation of the cylinders by removing the moving parts in each
VBE valve.
Before carrying out this operation, proceed as follows:
• remove the guard (5, Figure 1.4) from each cylinder unit;
• close vent valve (3, Figure 1.4);
• check that the cocks (1, Figure 1.4) on all cylinder solenoids are closed;
• remove the mobile equipment (plunger) from the solenoid as described below.
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).
Operations on the system
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Guidelines and specifications
EUROCARGO CNG
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).
Figure 1.8
149720
• 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.
• Fasten the empty coil holder sleeve with its o-ring (6) and fasten the ring nut at a torque of 28 Nm.
• Repeat the operations on all the VBE valves of the cylinders.
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Guidelines and specifications
1-13
Ventilation
• Half-open the cocks on the valves (1, Figure 1.4).
!
This operation ensures that pressurised gas enters the pipes: for this reason, exercise maximum
caution.
• Slowly open vent valve (3, Figure 1.4).
!
During this operation, cooling due to fast decompression could cause freezing.
Take particular care.
• Check that pressure gauge (2, Figure 1.4) indicates zero pressure in the system and ensure that it is not possible to start the
engine.
Where it is not necessary to replace the VBE valve after draining down the system fully, the previously removed parts that have
been set aside can be refitted (or replaced if necessary), proceeding as described in the next paragraph.
Operations on the system
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Guidelines and specifications
EUROCARGO CNG
Refitting moving parts of the solenoid
Remove the empty coil sleeve (1) with the o-ring (6).
Figure 1.9
149720
• 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.
• Renew the O-ring (6).
Figure 1.10
87392
• Fasten the coil holder sleeve ring nut and tighten at a torque of 28 Nm.
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Guidelines and specifications
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Figure 1.11
117663
• Check that coil (4) does not present signs of damage. If necessary, perform the checks described in the chapter ”VBE 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 a new o-ring (2) 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 “Emptying the gas system” chapter.
Figure 1.12
138256
• Remove the screws (1) and remove the cover (2).
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Guidelines and specifications
EUROCARGO CNG
Figure 1.13
6
5
7
149722
• Loosen the fittings (1 and 3) and disconnect the pipes (2 and 4) from the VBE valve fittings (5).
• Disconnect the electrical connection (7) from the coil (6).
Figure 1.14
138259
• 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.
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1.3.5
Guidelines and specifications
1-17
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, page 1-7) 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.
!
Before restoring system operation, have a HYDRAULIC LEAK TEST carried out at an IVECO
Afersales Service centre.
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.
!
Before restoring system operation, have a HYDRAULIC LEAK TEST carried out at an IVECO
Afersales Service centre.
Operations on the system
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Guidelines and specifications
1.3.6
EUROCARGO CNG
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.
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Guidelines and specifications
1-19
Cylinders
1.4
Cylinders
Figure 1.15
138265
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 (→).
CNG ONLY - DO NOT USE AFTER
FABER
/
/
(3)
E
110R(8)
L
(4)
CNG-1
(9)
(1)
.
(2)
KG
.
MPa15°C/
.
(7)
(5)
(6)
/
USE ONLY FABER APPROVED
MPa
(10)
(1) = expiration month,
(2) = expiration year, after 20 years
(3) = FABER serial numbers
(4) = rated cylinder capacity in litres
(5) = cylinder weight in kg
(6) = working pressure in MPa (15 ˚C)
(7) = test pressure in MPa
(8) = country where the cylinder was approved
(9) = ECE type approval number
(10) = test month/year
Cylinders
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Guidelines and specifications
1.4.1
EUROCARGO CNG
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
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1.4.2
Guidelines and specifications
1-21
Cylinder replacement
Removal
Before disconnecting the cylinders, empty the system completely following the procedure described
in the ”Emptying the gas system” chapter.
!
Figure 1.16
8
149723
• Remove guard (8) and disconnect the VBE valve (6) as described in paragraph 1.3.4.
• Hoist the side cylinder with a cable (5).
• Remove bolts (7 and 4), disconnect brackets (2) and use a lift to remove cylinder (5).
• Then disconnect upper cylinder (1) and lower cylinder (3) in the same way.
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.
!
Before restoring system operation, have a HYDRAULIC LEAK TEST carried out at an IVECO
Afersales Service centre.
Cylinders
Printed 603.95.141
Base - 11/2010
1-22
Guidelines and specifications
EUROCARGO CNG
Relays / Fuse holder control unit (IBC3)
1.5
Relays / Fuse holder control unit (IBC3)
1.5.1
Fuse
Figure 1.17
A
F
B
G
C
H
D
I
E
L
147944
Red fuse holder (70000/1)
Ref.
Function
1
Accessory compartment/rotary lights/ TOLL COLLECT
2
Medium roof/electric hatch cab lighting
3
4
5
Emergency bulb/ EM (Expansion Module)
6
Heated seats / TELMA / TELMA retarder cut-out from brake pedal
Delivery (A)
10
10
10
25
10
10
Terminal
+30
+30
+30
+30
+15
+15
Delivery (A)
30
30
20
Terminal
+30
+30
+30
10
+15
10
20
+Bat
+Bat
Delivery (A)
15
15
10
10
10
10
Terminal
+30
+30
+30
+30
+15
+30
Brown fuse holder (70000/2)
Ref.
1
2
3
4
5
6
Function
Heated windscreen
Heated windscreen
Headlight washer
Heated windscreen / central locking / TOLL COLLECT load flap/ navigation
system / 8-way fuse holder control (70001)
POTR / refrigerator
Central locking/load flap
Black fuse holder (70000/3)
Ref.
1
EM (Expansion Module)
2
EM
3
EM
4
EM
5
Allison gearbox
6
Allison gearbox / SW1
Function
Relays / Fuse holder control unit (IBC3)
Base - 11/2010
Printed 603.95.141
EUROCARGO CNG
Guidelines and specifications
1-23
Figure 1.18
A
F
B
G
C
H
D
I
E
L
147945
8-way fuse holder control (70001)
Ref.
1
2
3
4
5
6
7
8
Function
Control unit MF3
Gas system reducing valve control solenoid / Gas system wastegate /
Lambda sensor for pre and post catalytic converter gas system
Electronic ignition for gas system (cylinder ignition coils)
Electronic ignition for gas system (cylinder ignition coils)
MF3 control unit/ Gas system power supply relay / Relay to prevent
start-up if gas feed flap open
Relay controlling solenoid activation for gas system
Relay controlling solenoid activation for gas system
Control unit MF3
Delivery (A)
15
Terminal
+15
10
+15
5
5
+15
+15
5
+15
5
20
5
+15
+30
+30
Relays / Fuse holder control unit (IBC3)
Printed 603.95.141
Base - 11/2010
1-24
Guidelines and specifications
EUROCARGO CNG
Figure 1.19
A
F
B
G
C
H
D
I
E
L
147940
Fuses IBC3
Ref.
Function
F1
Reversing light/headlamp alignment corrector
F2
Heater/air conditioner unit
F3
VCM control unit
F4
Tachograph/Cluster (IC)
F5
ABS control unit
F6
Trailer ABS
F7
Heated mirrors / PDM / DDM
F8
Ignition relay
F9
Bodybuilders
F10
Horn
F11
Voltage reduction unit/radio receiver set
F12
Heated drier/ Electric mirror control unit
F13
ECAS control unit
F14
Cigar lighter/30 pin diagnostic connector/OBD connector.
F15
Bodybuilders/trailer ABS/FMS/radio receiver set
F16
Electric windows
Delivery (A)
10
20
10
5
20
20
20
20
10
10
20
10
10
10
5
20
Terminal
+15
+15
+30
+Bat
+30
+30
+30
+30
+30
+30
+30
+15
+30
+30
+15
+15
Relays / Fuse holder control unit (IBC3)
Base - 11/2010
Printed 603.95.141
EUROCARGO CNG
1.5.2
1-25
Guidelines and specifications
Minirelay set (black)
Figure 1.20
A
F
B
G
C
H
D
I
E
L
147940
Ref.
A
B
C
D
E
F
G
H
I
L
Description
Engine ignition relay
Remote switch for activating loads with key inserted
Vehicle diagnostic relay (+15 enablement from diagnostic instrument)
Horn relays
Relay for heated rear view mirror activation (opt.)
Relay to activate tailboard warning light (opt.)
Relay to prevent start-up if tailboard on (opt.)
Timer for heated windscreen
Relay for gas system power supply
Relay to prevent start-up if fuel feed flap open (NC)
Component
code
25200
25894
25705
25805
25813
25551
25550
25818
25918
25752A
Relays / Fuse holder control unit (IBC3)
Printed 603.95.141
Base - 11/2010
1-26
Guidelines and specifications
1.5.3
EUROCARGO CNG
Microrelay set (yellow)
Figure 1.21
A
F
B
G
C
H
D
I
E
L
147940
Ref.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
Description
Interior light activation relay (medium roof)
Remote headlight washer consent switch
TGC excitation relay
TGC opening relay
Relay for TELMA electronic retarder activation warning light
ECAS relay switch from box
ECAS relay switch from box
ECAS relay switch from box
ECAS relay switch from box
Allison relay
Allison relay
Electric hatch opening relay
Electric hatch closure relay
Relay for deactivating TELMA electric retarder with ABS on
CCE relay
CCE relay
CCE relay
Relay to prevent start-up if gas feed flap open (NO)
Relay controlling solenoid activation for gas system
Relay for activating brake lights with TELMA electric retarder on
Component
code
25803
25740
25202
25202
58054
25351
25352
25104
25752B
25921
25045
Relays / Fuse holder control unit (IBC3)
Base - 11/2010
Printed 603.95.141
EUROCARGO CNG
1.5.4
Guidelines and specifications
1-27
Supplementary fuses
The supplementary fuse box is located near the batteries and TGC and its purpose is to supply fuse-protected +30 and +Bat
power supplies to the vehicle’s electrical circuits, excluding the power circuit.
Prise open the two clips on the cover of casing (1) to gain access to the fuses inside.
Figure 1.22
1. Supplementary fuse box
149721
(A) = Long wheelbase version
(B) = Short wheelbase version
Figure 1.23
1
2
3
4
149725
Ref.
1
2
3
4
Description
MET control unit +30 positive
Cab positive pin +30 (PPC)
+30 Remote control switch for methane system supply
Direct battery positive (+bat for IBC3)
Flow rate (A)
80
80
30
30
Relays / Fuse holder control unit (IBC3)
Printed 603.95.141
Base - 11/2010
1-28
Guidelines and specifications
EUROCARGO CNG
Relays / Fuse holder control unit (IBC3)
Base - 11/2010
Printed 603.95.141
EUROCARGO 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
2-6
2.2.2
Normal PTO operation - green zone
2-7
2.2.3
Full power PTO operation - blue zone
2-7
2.2.4
PTO during driving - yellow zone
2-8
2.3
Electronic PTO setup
2-9
2.3.1
Expansion Module (EM)
2-9
2.3.2
Vehicle Control Module (VCM)
2-9
2.3.2.1
Advanced settings - PTO modes
2-9
2.3.2.2
Advanced settings - Body assembler
2-10
2.3.2.3
PTO Mode 1...3
2-11
Index
Printed 603.95.141
Base - 11/2010
2-2
PTO management
EUROCARGO CNG
Index
Base - 11/2010
Printed 603.95.141
EUROCARGO CNG
PTO management
2-3
22222.
Introduction
2.1
Introduction
IVECO Tector 6 Compressed Natural Gas (CNG) engine is Spark Ignition engine working in Otto process.
It uses 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 603.95.141
Base - 11/2010
2-4
PTO management
EUROCARGO CNG
Mechanical power take---off (PTO) installation, maximum power take---off
2.2
Mechanical power take-off (PTO) installation, maximum power take-off
The PTOs available for Diesel engines are also suitable for CNG engines, apart from the Multipower PTO on the flywheel.
Although it is possible to have torque take-offs from the transmission and the front part of the engine (see chapters 4.4 and 4.5
of “Bodybuilders instructions“ for Eurocargo M.Y. 2008), take-offs from the gearbox are the most recommendable.
Power take-off from gearbox
According to the type of gearbox, drive may be taken from the layshaft via flanges or fittings located to the rear, side or lower
part of the gearbox.
Table 1 shows available torque levels for the different types of gearbox/power take-off combinations, depending on the ratios
between output rpm and engine rpm.
IVECO must authorise high torque take-offs for sporadic use, according to the type of application.
When applied to the gearbox, the PTO must normally be used with the vehicle at a standstill and must be engaged and released
with the clutch disengaged. When the PTO must be used with the vehicle in motion, no gearshift must be carried out in order to
avoid excessive stress on the synchronisers.
One example of this type of mission is the collection of solid urban waste (SUW) where, due to the action of the compactor and
simultaneous progress of the vehicle over distances of a few hundred metres, it is necessary to select and maintain a ’short’ gear
ratio, normally second gear. For long transfers when fully laden, the power take-off must be disengaged, due also to the type of engine
delivery.
For transmissions with a torque converter, the power take-offs used on the manual gearboxes may normally be used. Note, however,
that when engine rpm is lower than approximately 60% of the maximum value, the converter system is in the hydraulic operating
stage. During this stage, the power take-off rpm may fluctuate according to the amount of power taken off even if engine rpm is
constant.
Direct application of pumps
When pumps or other user devices are applied directly to the power take-off, i.e. with intermediate shafts, it is advisable to check
that the static and dynamic torques exercised by the weight of the pump and power take-off are compatible with the gear casing
wall strength.
Where the gearbox is applied integral with the engine, the value of the additional weights must also be checked for inertia purposes
so that resonance effects are not set up in the power unit within the engine operating speed range.
Observe values in Table 1 for torque take-offs.
!
During prolonged use, the gearbox oil temperature must not exceed 120 ˚C and water temperature
must not exceed 100 ˚C.
Not all types of power take-offs available on the market are suitable for continuous use. The specific
instructions for the power take-off must be followed during use (working period, breaks etc.).
Mechanical power take-off (PTO) installation, maximum power take-off
Base - 11/2010
Printed 603.95.141
EUROCARGO CNG
PTO management
2-5
Power take-off from gearbox data
Table 1 shows the PTO types tested by IVECO.
Application of a PTO after vehicle production requires programming of the BC (Body Computer) as well as some operations on
the electrical and air system.
Before applying a PTO, it is therefore advisable to consult 4.6 “PTO management” in “Bodybuilders instructions” for Eurocargo M.Y.
2008“.
Electronic control unit reprogramming operations must be carried out using the appropriate diagnostic tool (available from IVECO
dealerships and IVECO authorised workshops) and providing information on the PTO used.
Table 1 - PTO on gearbox tested by IVECO
PTO TYPE
6S 700 TO
9S 75 TD
Position
Opt.
Version
Installation
position
Rotation
direction
Ratio
Output
torque
[Nm]
Rear
5035
Pump
Central
Clockwise
0.57
600
Rear
5042
Pump
Rear
(right)
Anti
clockwise
0.73
350
Rear
5455
Pump
Rear
(central)
Anti
clockwise
0.95
450
Rear
5047
Pump
Rear
5205
Rear
ALLISON 3000
Rotation
direction
Ratio
Output
torque
[Nm]
Rear
(right)
Anti
clockwise
0.92
410
Pump
Rear
(central)
Clockwise
0.62
600
5210
Pump
Rear
(base)
Anti
clockwise
0.79
430
Side
6392
Pump
Left side
Side
6392
Pump
Left side
Rotation
direction
Ratio
Output
torque
[Nm]
Anti
clockwise
0.93
600
ALLISON 2500
Rotation
direction
Ratio
Output
torque
[Nm]
Anti
clockwise
0.82
270
When any PTO is ordered, option 2463 (Cruise Control) and opt. 4572 (Expansion Module) must always be included.
Mechanical power take-off (PTO) installation, maximum power take-off
Printed 603.95.141
Base - 11/2010
2-6
PTO management
2.2.1
EUROCARGO CNG
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 2.1
149748
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 - 11/2010
Printed 603.95.141
EUROCARGO CNG
2.2.2
PTO management
2-7
Normal PTO operation - green zone
From 1150 rpm to 1600 rpm (engine output rotational speed)
From 0 Nm to 375 Nm of PTO torque application (calculated on engine output)
The engine operates in “configurable rpm 1, 2 or 3” mode with engine speed set between 1150 and 1600 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 1250 rpm to 1600 rpm (engine output rotational speed)
From 375 Nm to engine max torque applied by PTO (calculated on engine output)
The engine operates in “configurable rpm 1, 2 or 3” mode with engine speed set between 1250 and 1600 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/s (in order to avoid engine stall). This means that full torque
(650 Nm) can be reached earliest after 13 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 2.2
149748
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 603.95.141
Base - 11/2010
2-8
PTO management
2.2.4
EUROCARGO CNG
PTO during driving - yellow zone
/
From 780 rpm to 2900 rpm (engine output rotational speed)
From 0 Nm to 300 Nm PTO torque application (calculated on engine output)
From 0 kW to 35 kW PTO power request.
The engine operates in “PTO 1, 2 or 3 mode” without set rpms, except for minimum engine speed between 780 and 850 rpm.
A high engine speed limit may be applied, but not below 2000 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 > 180 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/s.
Mechanical power take-off (PTO) installation, maximum power take-off
Base - 11/2010
Printed 603.95.141
EUROCARGO CNG
PTO management
2-9
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.
Chapters “4.6.2” and “4.6.3” of the IVECO Eurocargo Bodybuilder Instructions are 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 “4.6.2 RPM 0 mode (driving mode)”
of IVECO Eurocargo Bodybuilder Instructions is valid.
The VCM PTO programming has the following tree structure
Figure 2.3
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 2.4
The settings in this chapter are generic for all PTO modes.
The following values have to be set.
Electronic PTO setup
Printed 603.95.141
Base - 11/2010
2-10
PTO management
EUROCARGO CNG
Table 2
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 2.5
The advanced Bodybuilder interface settings are not CNG specific and can be used like in a Diesel vehicle.
Electronic PTO setup
Base - 11/2010
Printed 603.95.141
EUROCARGO CNG
PTO management
2-11
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 3
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 1250...2900 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 780 rpm
do not exceed 150 rpm of Idle Engine Speed)
mode)
Do not modify
Maximum Torque
(default 2500 Nm)
High engine speed limit 1250...2900 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 controlCurve 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
2000...2900 rpm
780...850 rpm
Do not modify
(default 2500 Nm)
2000...2900 rpm
0
15 km/h
ON
ON
2 km/h
ON
ON
ON
ON
ON
ON
OFF
OFF
ON
ON
Electronic PTO setup
Printed 603.95.141
Base - 11/2010
2-12
PTO management
EUROCARGO 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)
1150...1600 rpm (green zone)
Engine speed control target 1250...1600 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
Automatic transmission can
OFF
override 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 - 11/2010
Printed 603.95.141