adr80/03 lng system operator's manual

ADR80/03 LNG System Operator’s Manual

NATURAL GAS ENGINES FOR HEAVY-DUTY TRUCKS

GX

Page ii

Emergency Situations•Fireon-boardthevehicle.

•Severenaturalgasleak.

•Anycircumstancerequiringassistancefromemergencypersonnel.

Recommended Emergency Response Procedure

1. Findasafeplacetopullover.

2. Turnoffengine.

3. CallemergencyrespondersandinformthemthatLNGandCNGareonboard.

4. Clearandsecurethelargestpracticalperimeter.

5. Informshop/dispatch.

Gas Leak Classification and ResponseSevere:•UncontrolledspillorsprayofLNG.

•Aleakwhichresultsinalargevaporcloud.

•Anyleakwherethevehicleislocatedinaplacewheregasmayaccumulate.

•Anyleakwhereasourceofignitionisincloseproximitytothevehicle.

Response:followtheRecommendedEmergencyResponseProcedure

Significant:•On-boardgasdetectorisinalert(redindicatorlightandalarm).

•Noother“Severe”conditions.

Response:seeSection 5.2—Gas Detection Monitor, Table 2: Gas detection interpretation

Trace:•On-boardgasdetectorisintracealarm(yellowindicatorlight).

•Noother“Severe”or“Significant”conditions.

Response:seeSection 5.2—Gas Detection Monitor, Table 2: Gas detection interpretation

Driver Safety – Quick Reference Page

Page iii

ThisguidecontainsinformationforthecorrectandsafeoperationofyourtruckequippedwiththeWestport HDADR80/03liquefiednaturalgas(LNG)system(“Westport HDSystem”).

ThisguideprovidesthefollowinginformationspecifictotheWestport HDSystem:

•Hardwareoverview

•Operatingproceduresandguidelines

•Safety

•Fuelingprotocol

•Maintenanceandcare

Theinformation,specifications,andrecommendedmaintenanceguidelinesinthismanualarebasedoninformationineffectatthetimeofprinting.Everyprecautionhasbeentakentoensureitsaccuracy.Westportanditsaffiliatesassumenoresponsibilityforerrorsinthisdocument,omissions,ortheirconsequences.Theinformationissubject

Forewordtochangewithoutnotice.Allrightsreserved.Nopartofthisdocumentmaybereproduced,storedinaretrievalsystem,ortransmittedinanyform,byanymeans,withoutthepriorwrittenpermissionofWestport.

Keepthismanualwiththevehicleatalltimes.Iftheequipmentistradedorsold,providethemanualtothenewowner.

Ifyouhaveanyquestionsabouttheinformationinthisguide,orifyouneedserviceassistance,pleasecontacttheWestport HDserviceteam.

Australia

E-mail: [email protected]

Websites: service.westport-hd.com www.westport-hd.com

Page iv

Table of ContentsDriverSafety–QuickReferencePage ii

Foreword iii

TableofContents iv

ListofFigures/ListofTables v

Section1–Introduction 6

Section2–ComponentIdentification 10

Section3–DescriptionoftheWestportHDSystem 14

Section4–Pre-TripInspection 23

Section5–VehicleOperation 28

Section6–WestportHDSystemSafetyPrecautions 37

Section7–SafeLNGTruckFueling 43

Section8–WestportHDSystemMaintenanceandCare 51

Section9–DiagnosticsandTroubleshooting 59

Section10–ExhaustAftertreatment 62

Section11–LNGPropertiesandHandling 64

AppendixA–DailyLogSheet(Sample) 70

AppendixB–TowingandRecovery 72

AppendixC–ContactInformation 73

Page v

List of Figures List of TablesFigureA: ADR80/03dataplatemountinglocations 11

FigureB: LocationoftheESN 12

FigureC: Enginecontrollerdataplate 12

FigureD: LNGtankdataplatelocations 13

FigureE: ADR80/03engine 17

FigureF: LNGtankshroud 19

FigureG: Ventstacks,filter,anddrainport 21

FigureH: Typicalremotefillpanel 22

FigureI: WestportLNGDriverDisplay 29

FigureJ: LNGtankcommunicationerror 31

FigureK: Activefaultcodescreen 31

FigureL: Systempressuresscreen 32

FigureM: Methanegasdetectordisplay 32

FigureN: LNGtanksafetyvalves 40

FigureO: High-pressureaccumulatorplumbing 40

FigureP: LNGtankmanualvalves 41

FigureQ: LNGtankshroudlabels 49

Table1: WestportDriverDisplaymessages 30

Table2: Gasdetectioninterpretation 33

Table3: Automaticreliefvalvesanddevices 39

Table4: Manualvalves 41

Table5: LNGtankvolumes 58

Section 1 – Introduction

Section 1 – IntroductionSection Contents

Acronyms and Abbreviation 7

Illustrations and Images 8

Notation 8

General Safety Instructions 8


1.1 Acronyms and AbbreviationThefollowinglistcontainssomeoftheacronymsandabbreviationsusedinthismanual.

ADR AustralianDesignRules

Bar pressureunit

°C degreesCelsius

CNG compressednaturalgas

DLE dieselliterequivalent

DPF dieselparticulatefilter

DRP dieselrailpressure

ECM enginecontrolmodule

ECU electroniccontrolunit

ESD emergencyshut-down

ESN engineserialnumber

EPA EnvironmentalProtectionAgency

°F degreesFahrenheit

FCM fuelconditioningmodule

GRP gasrailpressure

GSP gassystempressure

HD heavyduty

HPDI high-pressuredirectinjection

km/h kilometersperhour

L liters

LEL lowerexplosivelimit

LHS lefthandside

LNG liquefiednaturalgas

MPa megapascal

mph milesperhour

MSDS MaterialSafetyDataSheet

NFPA NationalFireProtectionAssociation

NG naturalgas

OEM originalequipmentmanufacturer

PPE personalprotectiveequipment

PRV pressurereliefvalve

psi poundspersquareinch

RHS righthandside

ROD runondiesel

rpm revolutionsperminute

TSN tankserialnumber

ULSD ultra-lowsulfurdiesel


1.2 Illustrations and ImagesManyoftheillustrationsusedinthismanualrepresentgenericconfigurations,andmaynotlookexactlylikethepartsusedinyourapplication.

1.3 NotationThefollowingnotationhasbeenusedthroughoutthismanualtohighlightimportantinformation.

WARNING! Serious personal injury or extensive property damage can result if the warning instructions are not followed.

CAUTION! Minor personal injury can result or a part, an

assembly, or the engine can be damaged if the caution instructions are not followed.

NOTE: Providesadditionalinformationofanon-safetyrelatednature.

1.4 General Safety InstructionsWARNING!

Improper practices, carelessness, or ignoring the warnings can result in serious personal injury or death

ReadandunderstandallofthesafetyprecautionsandwarningsbeforeusingaWestport HDSystemequippedvehicle.Thissectioncontainsthegeneralsafetyprecautionsthatmustbefollowedtoprovidepersonalsafety.

•Naturalgasislighterthanairandcanaccumulateinenclosedspaces,suchasunderthehoodorawnings.Ifthereisanignitionsource,anexplosioncouldresult.

•Naturalgasiscolorlessandodorless.Somenaturalgassuppliersaddanodoranttonaturalgas.However,liquidnaturalgastypicallydoesnotcontainodorant.

•Parking outside is mandatoryduetonormalventingofnaturalgas.

•Westport HDpoweredtrucksareequippedwithagasdetectionmonitor.Youmustchecktheoperationofthegasdetectionmonitorandlistenforsoundsofaleak.Ifyoudetectsignsofaleak,seeredoryellowstatuslights,hearagasalarm,orcannotseethegreenpowerlightonthedetector;donotenteroroperatethetruck.Notifytheshopfromoutsidethetruck.


•Donotstayinanaturalgasvaporcloud.Naturalgasdisplacesoxygenandcancauseasphyxiation.

•TheWestport HDSystemcontainshighpressuregas,liquid,andcryogenicfluid—evenwhenthetruckisturnedoff.NounauthorizedoruntrainedpersonshouldeverattemptmaintenanceorrepairsonaWestport HDpoweredtruck.

•Westport HDSystemrepairsmustbecompletedonlyatcertifiedWestportcenters.

•Onlyoperate“ServiceOnly”valvesifyouareaqualifiedWestport HDSystemstechnician.

•Naturalgasvaporisflammablewhenmixedwithair,andisignitablebystaticdischarge.Ensuretruckisproperlygroundedduringfueling.Donotsmokeduringfueling.

•DamagetotheWestport HDSystemcanoccurifthecoolantmixtureisincorrect.Ensurecoolantmixturecontainssufficientglycollevels.

Section 2 – Component Identification

Section 2 – Component IdentificationSection Contents

GX Engine and Engine Controller Dataplate Locations 11

Engine Identification Dataplate 12

Engine Controller Identification Dataplate 12

LNG Tank Identification Dataplate 13


2.1 GX Engine and Engine Controller Dataplate Locations

TheWestportengineidentification,andtheenginecontrollerdataplatesarebothlocatedontheADR80/03engine.

Figure A: ADR80/03 engine and controller dataplate mounting locations

Engine Identification Dataplate

Engine Controller Dataplate


2.1.1 Engine Identification DataplateTheenginedataplateislocatedontopoftherockerlevercover,andprovidestheengineserialnumber(ESN)andotherimportantinformationabouttheengine.TheenginedataplatemustnotbechangedunlessapprovedbyWestport.

HavetheESNavailablewhencommunicatingwithanauthorizedWestportservicecenter.Theinformationonthedataplateisnecessarywhensourcingserviceparts.

Figure B: Location of the ESN

2.1.2 Engine Controller Identification DataplateTheenginecontrollerislocatedonthecoldsideoftheenginebelowtheengineidentificationdataplate.Thedataplateismountedonthefrontofthecontroller.

PART NUMBER: EEEEEEE ENGINE SERIAL NUMBER: BBBBBBBBSERIAL NUMBER: FFFFFFF CALIBRATION NUMBER: XXXXXXXXDATE CODE: GGGGGGGG"!WARNING! SOFTWARE MODIFICATIONS TO BE MADE BY WESTPORT PERSONNEL ONLY"

Figure C: Engine controller dataplate

Thecontrollerdataplate(see Figure C: Engine controller dataplate)includesthefollowingimportantinformation:

•serialnumber

•calibrationnumber


2.2 LNG Tank Identification DataplateTheWestportLNGtankdataplateprovidesthetankserialnumber(TSN)andotherimportantinformationabouttheLNGtank.TherearetwopossiblelocationsfortheLNGtankidentificationdataplate,dependingonthemanufacturer(see Figure D: LNG tank dataplate locations):

PleasehavethetankserialnumberavailablewhencommunicatingwithanauthorizedWestportservicecenter.

Thisinformationisnecessarywhensourcingserviceparts.

Figure D: LNG tank dataplate locations

TSN

On the front head inside the tank shroud

CERTIFIED BY: BTIC

RT-4W

psi AT(MAX. ALLOWABLE WORKING PRESSURE)

(MIN. DESIGN METAL TEMPERATURE)

psiAT

(YEAR BUILT)

20

(MANUFACTURE'S SERIAL NUMBERS)

°F

°F

TSN

On the ring adjacent to the tank shroud

Section 3 – Description of the Westport HD System

Section 3 – Description of the Westport HD SystemSection Contents

What the Westport HD System Is 15

How the Westport HD System Works 15

Location of Westport HD System Components 16

Inside the Cab 16

Inside the Engine Bay 16

Outside the Engine Bay 18


3.1 What the Westport HD System IsTheWestport HDSystemisafuelsystem,whichallowsdieselenginestousenaturalgasastheirprimaryenginefuel.

Bysubstitutingover95%ofdieselfuelwithcleanburningnaturalgas,atruckusingtheWestport HDSystemmaintainsthesamepowerandperformanceasanequivalentdiesel-onlytruck.

3.2 How the Westport HD System WorksLNGisdrawnfromtheLNGtankandispressurizedbythetank-mountedLNGpump.Usingwarmenginecoolant,avaporizer(heatexchanger)warmsthehigh-pressureLNG,changingittohigh-pressurenaturalgas.Thishigh-pressuregasiscalledcompressednaturalgas(CNG)andistheprimaryfuelfortheengine.TheCNGisfedtothefuelconditioningmodule(FCM),andregulatedtotheinjectors.

Simultaneously,dieselisdrawnfromthedieseltanktoanengine-mounted,high-pressuredieselpump.Thehigh-pressuredieselisfedtotheFCMandregulatedtotheinjectors.

Insidetheengine,aWestportHPDIinjectordeliversasmallamountofdieselfuel,andalargeamountofcompressednaturalgasintotheenginecombustionchamber.Theigniteddieselfuelprovidesignitiontothenaturalgas,whichprovidestheenginepowerstroke.


3.3 Location of Westport HD System Components

Westport HDSystemcomponentsarelocatedinthreelocationsonthetruck:

3.3.1 Inside the CabTheWestport HDSystemhastwosystemmonitoringdisplays:

•Westport LNG Driver DisplayIndicatestheWestport HDSystemstatus;includingLNGfuellevel,systemfaultmessages,activefaultcodes,andsystemparameters(seeSection 5.1—Westport LNG Driver Displayformoreinformation).

•Gas Detection Monitor(OEMSupplied)Monitorsandindicatesnaturalgasleaksfromthesystemintwokeyzones:insidethecab,andinsidetheenginebay.

3.3.2 Inside the Engine BayTheWestport HDSystemhasthefollowingcomponentsintheenginebay:

•Fuel Conditioning Module Amanifoldthatcontrolspressureandsupplyofnaturalgasanddieseltotheengine.

•High-Pressure Diesel Pump Anenginemounted,beltdrivenpump,whichprovideshigh-pressuredieseltotheFCM.

•HPDI Injectors HPDIinjectorsdeliverbothdieselandnaturalgasintothecombustionchamber.

•Engine Oil Fill Theengineoilfillislocatedonthelefthandsideofthecylinderhead,nearthevalverockercover.

•Hydraulic Reservoir(OEMSupplied)Mountedintheenginebay,thereservoirprovideshydraulicfluidfortheLNGpumpaswellasthepower-assistedsteeringsystem.

•High-Pressure Hydraulic Pump(OEMSupplied) Adualvanehydraulicpumpthatprovideshigh-pressurehydraulicfluidtodrivetheLNGpump(s),andthepowerassistedsteeringsystem.


Figure E: ADR80/03 engine

Fuel conditioning

module

Engine control

unitHigh-pressure

diesel pump Engine oil fill

•Hydraulic Oil Cooler(OEMSupplied)Mountedinthecoolingpack,thishardwarecoolsthehydraulicfluid.

•Dosing Pump(OEMSupplied) ThedosingpumpsuppliesfueltotheintegratedCumminsdieselparticulatefilter(DPF)aspartoftheexhaustaftertreatmentsystem(seeSection 10—Exhaust Aftertreatmentformoreinformation).

•Westport HD System Controls Consistsoftwoon-boardelectronicsmodules,whichcontroltheWestport HDSystemincluding:HPDIinjectors,andLNGpump.Athirdenginecontrolunitismountedontheengine.


3.3.3 Outside the Engine Bay•LNG Storage Tank(s) OneormorestainlesssteelLNGtanksaremountedontheframerailand/ormountedtransverselybehindthevehiclecab.BecausethetankholdsLNG,whichisextremelycold,itisconstructedasadouble-walledvessel.Theinnerandouterwallsareseparatedbyinsulationandavacuumspacetoprovideprotectionfromtheoutsideenvironment.ThisinsulationkeepstheLNGtemperaturelowforlongerperiodsoftime.Westportofferssingleormultipletankconfigurations.

•LNG Pump TheLNGpumpismountedinsidethetank.Thepumpdrawsandpressurizesliquefiednaturalgas,whichisvaporizedwiththeaidofwarmenginecoolantintocompressednaturalgasthatisdeliveredtothehighpressureaccumulator(see“Figure F: LNG tank shroud”).

•LNG Tank Valves(see“Figure F: LNG tank shroud”)

� Automatic Pressure Relief Valves (PRV) LocatedinsidetheLNGtankshroud,thepressurereliefvalvesprotectthesystemfromover-pressure.Intheeventofanover-pressurecondition,thevalvesventtheexcessgas.TheLNGtankisequippedwithaprimaryandasecondaryreliefvalve:

�Primary Relief Valve Avalvedesignedtoopenwhentankpressureexceeds16bar(230psi).Itclosesautomaticallywhentankpressurefallsbelow16bar(230psi).

�Secondary Relief Valve Avalvedesignedtoopeniftankpressureexceeds22 bar(315psi),iftheprimaryreliefvalvemalfunctions.Itisequippedwithasafetycapasavisualindicatorthattheprimaryvalvehasmalfunctioned,aswellastokeepdebrisandmoistureoutofthevalve.

� Automatic Tank Shutoff Valve ThevalveislocatedontheoutsideoftheLNGtankshroud,wheretheCNGexitsthetank.TheshutoffvalvepreventsCNGfromexitingLNGtank,shouldthedownstreampressuredropsbelow26bar(380psi),whiletheLNGpumpisnotoperating.


Figure F: LNG tank shroud

Secondary tank relief valve (22 bar / 315 psi)

Vent-to-station valve

LNG pump

Vent-to-atmosphere valve

Liquid drain valve

Automatic tank shutoff valve

Vent stack exhaust

Primary tank relief valve (16 bar / 230 psi) Vent system drain


� Manually Operated Valves LocatedinsidetheLNGtankshroud,includes:

� Vent-to-Station Valve Locatedinsidethetankshroudontheleft-handside,thisvalvecontrolsthereturnofexcessfuelvaportothestation.Theexcessvaporissafelyreturnedthroughthestation’sfuelhose,ordedicatedstationventlinepriortorefueling.SeeSection 7.6—VentingformoreinformationonventingLNGtanksforfueling.

� Vent-to-Atmosphere Valve Locatedinsidethetankshroudontheright-handside,thisvalvecontrolstheventingofexcesstankvaporsafelythroughthevehicleventstacktotheatmospherewhenitisnotpossibletoventtothestation.SeeSection 7.6—VentingformoreinformationonventingLNGtanksforfueling.

� Service Only Valves (Tobeoperatedbyqualifiedpersonnelonly)

� Liquid Drain Valve DrainsLNGfromthetankpriortoatankorpumpserviceorrepair.

�Accumulator High-Pressure Gas Shut-Off Valve Locatedneartheaccumulator,thisvalveisolatesthehigh-pressuregasintheaccumulatorduringdownstreamgassystemmaintenance.Thisvalveshouldonlybeoperatedbytrainedrepairpersonnelusingvalvelock-outproceduresduringmaintenanceorrepairs(see“Figure O: High-pressure accumulator plumbing”).

AdetaileddescriptionofthevalvesandtheirfunctionsisinSection 6.4—Manual Valves.

WARNING! The Westport HD System contains high-pressure gas,

liquid, and cryogenic fluids—even when the truck is turned off. No unauthorized or untrained person should ever attempt maintenance or repairs on a

Westport HD powered truck. Do not turn valves you are unfamiliar with. Serious high-pressure blast or

cryogenic burn injuries could occur.

•High-Pressure Accumulator Assembly(OEMSupplied)Thehigh-pressureaccumulator,containingCNG,istypicallymountedbetweentheframerails,orbehindthecab.ItisusedtoreducegaspressurepulsesinthesystemintroducedbytheLNGpump.High-pressuregas(CNG)isdeliveredfromtheaccumulatortotheengineforcombustion.


•High-Pressure Gas Filter(OEMSupplied)Thehigh-pressuregasfilterprovidesprimaryfiltrationforCNGenteringtheengine.ConsultyourOEMdocumentationforinformationregardingthefiltermountinglocation.

•Gas Vent Stacks(OEMSupplied)Theventstacksaresmallpipesthattypicallyrunupalongthebackofthecab.Theyserveasawayforexcessgastoescapesafelyupandawayfromthetruck.

Therearetwoventstacks:thefirstventstheLNGtanks;thesecondventstheenginegasrail,FCM,andaccumulatorpressure.Thesecondventstackisequippedwithafilteranddrainport.SeeFigure G: Vent Stacksforpossiblemountingconfiguration.

•Remote Fill Panel(OEMSupplied) Thispanelallowsmulti-tanksystemstobefueledfromonelocation.Theremotefillpanelisequippedwithventportsandagroundinglug(seeFigure H).Formoreinformationonfueling,pleaseseeSection7—SafeLNGTruckFueling.

Figure G: Vent stacks, filter, and drain port(other configurations possible)

Gas vent stacks

Vent stack filter

Drain port


Fuel nozzle

Vent line receptacle

Ground lug

Figure H: Typical remote fill panel(if equipped)

Section 4 – Pre-Trip Inspection

Section 4 – Pre-Trip InspectionSection Contents

Pre-Trip Inspection 23

Inside the Cab 23

Inside the Engine Compartment 25

Outside the Engine Compartment 25

Pre-Trip Summary 26


4.1 Pre-Trip InspectionTheWestport HDSystemrequiresregularmonitoringandmaintenancetoensuremaximumperformanceandsafety.Beforestartingyourtrip,completethepre-tripinspectiondescribedinthefollowingsections,inadditiontoyournormalrequiredtruckinspection.Thereisasamplepre-andpost-tripinspectionsheetinAppendix A—Daily Log Sheet.





4.1.1 Inside the CabBeforeenteringthetruck,checkthefollowingitems.

Before Entering the Cab:

1. Listenforanalarm.Ifyouhearanaudiblealarm,thisindicatesasignificantCNGleak—Donotenterthecab;notifyyourcertifiedWestportrepaircenter.

2. Lookforlightsonthegasdisplay.Ifredoryellowlightsareon,thisindicatesaCNGgasleak—Donotenterthecab;notifyyourcertifiedWestportrepaircenter.

3. Listenforanaudible(hissing)noise;itmayindicateaCNGleak—Donotstartthetruck;notifyyourcertifiedWestportrepaircenter.

After Entering the Cab:

Afterenteringthecab,checkthegasdetectionmonitorlocatedinthedashboard.SeeSection 5.2—Gas Detection Monitorwhichdescribesthefunctionofthegasdetectionindetail.

1. Checkforagreenpowerlightonthegasdetectiondisplay.Ifthegreenlightis[OFF],gasdetectionhasbeendisabled—Donotstartthetruck;notifyyourcertifiedWestportrepaircenter.

2. Checkforsensorfaultlightsonthegasdetectiondisplay.Iftheselightsare[ON],thisindicatesafaultwiththegasdetectionsystem—Donotstartthetruck;notifyyourcertifiedWestportrepaircenter.

3. Checkforredoryellowlightsonthegasdetectiondisplay.ThisindicatesaCNGleak—Donotstartthetruck;notifyyourcertifiedWestportrepaircenter.


4. Checktheoperationofthegasdetectorbypressingthe[PushtoTest]buttononthegasdetectionmonitor.Formoreinformationoncheckingandtestingthegasdetectionmonitor,seeSection 5.2—Gas Detection Monitor.

5. Checkthatrequiredsafetygearforfuelingisinplace,ifyourefuelthetruckyourself(seeSection 7.1—LNG Fueling Safety Equipment).

6. Turnthekeyswitchtothe[ON]positionandchecktheOEMdieselfuellevelgaugetoensurethatyouhavediesel.Section 8.2.6—Diesel Fuel Specificationcontainsinformationondieselfueltypeandexpectedusage.

7. Withthekeyswitchinthe[ON]position,checkLNGfuellevelsdisplayedontheWestportLNGdriverdisplay.SeeSection 8.2.1—LNG Composition forinformationonLNGfueltype.

8. Turnkeyswitchtothe[OFF]positiontocompletenextchecks.

4.1.2 Inside the Engine CompartmentWiththeengineoff,inspecttheenginebayforanyleakssuchasdieselfuel,engineoil,hydraulicfluid,ornaturalgas.ListenforthesoundofaCNGleak.

Checkthefollowing:

•Hosesandfittings

•Drainalldieselfuel-waterseparators

•Drainventstackfilter

•High-pressuredieselpumpandtheconditionofthebelt

•Hydraulicpumpandfittings

•FCM(fuelconditioningmodule)

•Hydraulicfluidlevel

•Hydraulicoilcoolerisunblockedandfreeofdebris

•Frontandsidesofengineforoilleaks.

Notethelocationofanyleaksorabnormalities,andhavethemrepairedbyyourlocalcertifiedWestportrepaircenterbeforeoperatingthetruck.


4.1.3 Outside the Engine CompartmentInspecttherestoftheWestport HDSystemcomponentsforexternaldamage,leaks,ortampering.

Checkthefollowing:

•High-pressuregasfilterlocatedneartheaccumulatorforleaksordamage

•LNGtankandvalvesforabnormalfrostoraudibleleaks

•Ventstackforexcessiveventing

•SafetycapispresentontheLNGtanksecondaryreliefvalve

•Vent-to-stationvalveisclosed.

Normaltankpressurecanvarybetween2barand16bar(30 psiand230psi).AdviseyourlocalcertifiedWestportrepaircenterifthepressurevariesaboveorbelowthenormalrange,orifthetruckventsfrequently.

NOTE: Theplasticsafetycapinstalledonthesecondaryreliefvalvekeepsmoistureanddebrisoutofthevalve.Theabsenceofthecapalsoindicatesthatthesecondaryreliefvalvehasbeenused,andapossiblemalfunctionoftheprimaryreliefvalve.Alwayscheckandreporttotheshopifthesecondaryreliefvalvecapismissingbeforestartingyourtrip(seeSection 6.3—Pressure Safety Devices).

NOTE: Ifyounoticemorefrostingthanusual,itmayindicatealeak.Notethefrostedareaandreportittotheshopimmediately.Anyleakmustberepairedbeforestartingthetruck.

NOTE: Ventingwillproduceanaudiblehissingsoundfromtheventstacks.Reportuncontrolledventingtotheshop,asrepairsmayberequired.

NOTE: ThereadingontheLNGtankpressuregaugehasno correlationtoamountoffuelinthetank.

WARNING! If tank pressure reads zero, notify the shop,

as this may indicate a NG leak.



Westport HD powered truck.


4.2 Pre-Trip Summary� Checkgasdetectionmonitorstatusbeforeenteringcab.

� Testgasdetectionmonitoroperationbypushing[PushtoTest]button.

� Checkenginecompartmentcomponentsforleaks,tampering,anddamage.

� Checkforrequiredfuelingsafetygear,ifplanningtorefuelyourself.

� CheckLNGanddieselfuellevels.

� CheckLNGtanksandframe-mountedcomponents.

� ChecksecondaryreliefvalvecapontheLNGtank(s).

� Checkvent-to-stationvalveisclosedontheLNGtank(s).

� Checkthehydraulicoilcoolerisunblockedandfreeofdebris.

Section 5 – Vehicle Operation

Section 5 – Vehicle OperationSection Contents

Westport LNG Driver Display 28

Screen Navigation 28

LNG Fuel Monitor and System Message Screen 28

Active Fault Code Screen 30

System Pressures Screen 31

Driver Display Contrast & Brightness Setting 31

Gas Detection Monitor (OEMSupplied) 31

Starting the Engine 33

Running on Diesel (ROD) Operation 33

Turning the Truck Off 34

Post-Trip Inspection 34

Parking—General and for Maintenance 35

Cold Weather Starting Procedure 35

Starting Procedure After Extended Shutdown 35


AWestport HDSystemequippedtruckisdrivenexactlylikeanequivalentdiesel-poweredtruckwithasimilarpowerbandandshiftingpoints.TheonlydifferencewhiledrivingistomonitortheWestportLNGDriverDisplay.

5.1 Westport LNG Driver DisplayTheWestportLNGDriverDisplaydisplaysinformationandmessagesaboutthestatusoftheWestport HDSystem.Thedriverdisplayhasthreescreens:theLNGFuelMonitorandSystemMessagescreen,theFaultCodescreenandtheSystemPressuresscreen.

LNG fuel tank level meter (showing 5/8 full)

Disabled pump indicator (pump not working)

Cold gas discharge temperature indicator (coolant temperature too low, usually accompanied with “Engine Warming Up...” message

Figure I: Westport LNG Driver Display(single tank example shown)

5.1.1 Screen NavigationUsethefollowinginstructionstonavigatebetweenthedifferentwindowsoftheDriverDisplay.Buttonsarereferredto[1]through[5],asshownlefttoright.

1. Pressanyofthebuttons[1]through[4]todisplaythebuttonlabels.

•Pressbutton[2]todisplaytheLNGFuelMonitorandSystemMessagescreen.

•Pressbutton[3]todisplaytheActiveFaultCodescreen.

•Pressbutton[4]todisplaytheSystemPressuresscreen.

2. Pressbutton[5]tohidethebuttonlabels.

5.1.2 LNG Fuel Monitor and System Message Screen

Thefuelmonitorandsystemmessagedisplayprovidestwoprimaryfunctions,displayLNGfuelstatus(upperwindow)andprovidethedriverwithsystemmessages(lowerwindow).

Theupperwindowshows:

•LNGfueltanklevelmeterandLNGpumpicon

•DisabledLNGpumpindicator(Xthroughthepumpicon)

•Coldgasdischargetemperatureindicator(snowflakeunderthepumpicon)


Fortrucksequippedwithmultipletanks,thetankiconwillflashtoshowwhichtankfuelisbeingdrawnfrom.

Thefollowingtablereviewsthemessagesdisplayedbythelowerwindowofthedriverdisplaysystemmessagescreen.

Table 1: Westport Driver Display messages

Message Type Cause Action

Please Stop Engine… Critical Alarm Significant engine issue Pull over, stop engine, call shop/service

Check for CNG Leak Critical Alarm Possible high-pressure gas leak Pull over, stop engine, call shop/service

Prepare to Stop Critical Alarm Loss of gas supply Prepare to pull over and stop

Engine Warming Up Max 6 MPH (10 KM/H)

Alarm1 Coolant not sufficiently warmed and/or accumulator hasn’t charged once since key-on

Wait before driving truck over 6 mph (10 km/h)

Low Fuel Level Alarm2 5% of fuel level remaining Monitor fuel level(s) & refill LNG tank(s)

LNG Tank # is empty Message No LNG fuel in tank Refill corresponding LNG tank

Check ECU Next Stop Message Active fault code stored in ECU Advise shop of message after return

On Diesel – Only XXX Seconds Remaining

MessagePossible fault in LNG System or no LNG fuel in tank

Engine running on diesel; pull over, wait for gas pressure build up, call shop/service

No CAN Messages MessageNot receiving communication from HPDI fuel system ECU

Call shop/service

(stripes on LNG fuel tank level meter) Display3 Fault with LNG tank communication Call shop/service

1. Alarm sounds if speed limit is exceeded.2. Alarm sounds for 1 second when low fuel level is initially reached, or fuel level is already low at key-on.3. See Figure J: LNG Tank Communication Error


NOTE: Aftertwominutesofinactivity,thedriverdisplaywillalwaysdefaultbacktotheLNGFuelMonitorandSystemMessagescreen.

NOTE: Shouldacriticalalarmbecomeactive,theLNGFuelMonitorandSystemMessagescreenwillbeautomaticallydisplayed.

Figure J: LNG tank communication error

5.1.3 Active Fault Code ScreenTheActiveFaultCodescreenisusedtodisplayWestport HDSystemspecificactivefaultcodes.

ThesefaultcodescanbeusedbytrainedservicetechnicianstodiagnoseissueswiththeWestport HDSystem.

Amaximumof11faultcodescanbedisplayedconcurrently.Whenafaultcodebecomesinactive,itisremovedfromthisscreen.

ACTIVE

3199

Figure K: Active fault code screen


5.1.4 System Pressures ScreenTheSystemPressuresscreenisusedtodisplayimportantpressuresfortheWestport HDSystem.

Thethreesystempressuresaredisplayedasfollows:

•GRP:Gasrailpressure,(bar)–Gaspressurepresentintheenginefuelrailandinjectionpressure.

•DRP:Dieselrailpressure,(bar)–Dieselpressurepresentintheenginefuelrailandinjectionpressure.

•GSP:Gassupplypressure,(MPa)–LNGpumpdischargeandaccumulatorpressures.

GRP=220.00barDRP=225.00barGSP=30.00MPa

Figure L: System pressures screen

5.1.5 Driver Display Contrast & Brightness SettingInordertoadjustthescreencontrastand/orbrightnesssettings,pressbutton[5].Usebuttons[1]to[4]toadjustcontrastandbacklightbrightnessasdescribedbytheon-screenmenus.Whencomplete,pressbutton[5]toexit.Thescreensettingswillbeautomaticallysaved.

5.2 Gas Detection Monitor (OEMSupplied)Westport HDpoweredtrucksareequippedwithnaturalgassensorsmonitoringtwozones:oneintheinteriorofthecab,andoneintheenginebay.Eachzoneonthegasdetectordisplayhasitsownsetofstatuslights.

Figure M: Methane gas detector display

Thefollowingtabledescribesthevariousalertsassociated


withthegasdetectionmonitor.

Table 2: Gas detection interpretation

Lamp Alarm Meaning Action

SENSOR FAULT

No Indicates that the sensor is not detected, or sending a fault from the corresponding location

Continue to drive, report to shop

TRACE No Indicates gas leak (>20% of LEL) near corresponding location

Continue to drive, monitor gas detector for change to alert, report to shop

SIGNIFICANT Yes Indicates gas leak (>50% of LEL) near corresponding location

Pull over, shut off engine, close accumulator isolation valve (if safe to do so), notify shop

If “INTERIOR” – exit and do not return to cab, unroll the window (if safe to do so)

If “ENGINE” – open hood (if safe to do so)

POWER No Green indicates display is working properly

n/a

Thegasdetectiondisplayhastwobuttons:

[Push to Test]:TestsLEDsandelectricalcircuits.

[Push to Silence]:Turnsofftheaudiblealarmwhenthedisplayisinalarm.

WARNING! Natural gas is colorless and odorless. You must check the operation of the gas detection monitor

and listen for sounds of a leak. If you detect signs of a leak, see red or yellow lights, hear a gas alarm, or

cannot see the green power light on the detector, do not enter or operate the truck. Notify the shop from

outside the truck.

NOTE: Ifgasdetectionmonitorisnotasshown,refertoOEMsupplementaldocumentation.


5.3 Starting the EngineTheengineshouldbestartedonlyafteracompletepre-tripinspection.ThestartingprocedureofaWestport HDpoweredtruckisthesameasaregulardieseltruck.Tostartthetruck,turnthekeytothe[START]positionandcranktheengineuntilitfires.SeeSection 9—Diagnostics and Troubleshootingiftheenginehasproblemsstarting.

NOTE: Whenyoufirststartthetruck,themessage“EngineWarmingUpMax6MPH(10KM/H)”isshownuntilthecoolantissufficientlywarmedandthehigh-pressureaccumulatorisfullycharged.Whilethismessageisshown,youcanbobtailthetruck(withnoloadortrailer)toamaximumof6mph(10km/h).Anaudiblealarmissoundedwhentruckexceedsspeedlimit.SeeSection 5.1—Westport LNG Driver Displayformoreinformation.

CAUTION! Exceeding speed limit while “Engine Warming Up Max

6 MPH (10 KM/H)” message is displayed may cause Westport HD System components to freeze up.

Start-Up Summary

1. Completepre-tripinspection.

2.Turnignitiontothe[START]positionandcrankengineuntilitfires.

3. WaitfortheWestportLNGDriverDisplaytoshowanormaldrivingscreen.

4. Donotexceed6mph(10km/h)while“EngineWarmingUp…”messageisdisplayed.

5. Checkcontrolsandgaugesbeforebeginningyourtrip.

6. Ifnofaultsormessages,youmaybegintodrive.

5.4 Running on Diesel (ROD) OperationWestport HDSystemequippedtruckshavetheabilitytostartandrunondieselincertainsituationswhenhigh-pressuregas(CNG)isnotavailabletotheengine.Thisprovidesaconvenientwaytostarttheenginefollowingservice,butbeforethetruckhasbeenrefueledwithLNG.TheRODmodemaynotbesufficienttogetthetruckofftheroadinanemergencysituation.

SwitchingtoRODisautomaticandrequiresnointeractionfromtheoperator.Thereisasignificantpowerdeficit,withonlyabout10%poweravailable.Never use this mode to drive the truck on roads or highways, or to pull a load.Continuousoperationondieselislimitedbya10minutetimer.


After10minutesofRODoperationthetruckwillautomaticallyattempttoswitchtoregularHPDIoperation.Ifsufficientgaspressureisstillnotavailabletotheengine,thetruckwillshutdown.SeeSection 5.1—Westport LNG Driver DisplayformoreinformationaboutRODmessagesfromthedriverdisplay.

IfyourtruckgoesintoRODoperationduringnormaldrivingyoushould:

1. Findasafespotandpullofftheroad;

2. IdletruckforafewminutesuntiltheRODmessageclears;and

3. Reporttotheshopaftertripcompletion.

IfyoucannotbringyourtruckoutofRODmode,youmaybeoutoffuelortheremaybeaproblemwithyourLNGsystem.ShutoffthetruckandcontactyourlocalWestportcertifiedrepaircenter(seeAppendix C—Contact Information).

AfteranextendedRODevent(5minutesorlonger)itisgoodpracticetochecktheventstackfilter(seeFigure G: Vent stacks).Ifthereisdieselinthefilter,drainanddisposeofthefuelinaccordancewithlocalrulesandregulations.

5.5 Turning the Truck OffWhenyourtripiscomplete,lettheengineidlefor2minutes,thenturnthekeytothe[OFF]position.

Youmaynoticeventingintheventstackbehindthecab.Itisnormalforthefuelsystemtoventasmallamountofgastotheatmosphereaftershutdown.Theventingshouldnotlastmorethan5seconds.Ifventingpersists,notifytheshop.

5.6 Post-Trip InspectionPerformthefollowingstepsaspartofyourpost-tripinspections:

1. ItisimportanttocheckandrecordtheLNGtankpressure.Tankpressurewillrisedependingonthetemperatureofthefuel,andtimesincefueling.

2. Lookandlistenforleaks.

3. EnsureWestport HDSystemcomponentsaresecurelymounted.

4. VerifythatthesecondaryreliefcapisoneachLNGtank(seeFigure F: LNG tank shroud).


5.7 Parking—General and for MaintenanceWARNING!

You must park outside! Never allow the truck to vent or leak in an enclosed space. The gas will rise and collect in areas where

there may be an ignition source. An explosion could result.

Parkingoutsideismandatory.Remember,thetankreliefvalveswillreleaseatapproximately16bar(230psi).ItisnormalfortheLNGtankpressuretoriseandperiodicallyventthroughtheventstacks.

Indoorparkingoroperationmaybeallowedprovidedthefacilityisproperlyequippedandthetruckisappropriatelypreparedtopreventanddetectanaccumulationofnaturalgasinacombustiblemixture.TruckandfacilitypreparationaredictatedbynationalcodessuchasNFPA30Aandotherlocalregulations.Alwayscheckwiththefacilitiesmanagertoseeifyourfacilityhastheappropriateequipment.

5.8 Cold Weather Starting ProcedureIncoldconditionstheenginemaystartindieselonly(ROD)operation,whiletheenginecoolantiswarmingup.Assuch,theoperatorshouldexpectlongerthanusual“EngineWarmingUp…”messagefromthedriverdisplay.SeeSection 5.4—Running on Diesel (ROD) Operationformoreinformation.

CAUTION! The use of ether as a cold climate starting aid is strictly prohibited for the Westport GX Engine and LNG System

and may lead to component damage.

5.9 Starting Procedure After Extended Shutdown

Afteranextendedshutdown,thetruckLNGtank(s)willbeempty,andthetruckwilllikelyhavetobetowedtothenearestLNGfuellingstation.SeeSection 7—Safe LNG Truck Fuelingformoreinformation.

Priortostarting,theoperatorshouldvisuallyensurethattheaccumulatorshut-offvalveisintheopenposition.SeeSection 6.4—Manual Valvesformoreinformation.

Section 6 – Westport HD System Safety Precautions

Section 6 – Westport HD System Safety PrecautionsSection Contents

Fuels 37

Liquefied Natural Gas (LNG) 37

Natural Gas (NG) Vapor and Compressed Natural Gas (CNG) 37

Diesel 38

High Pressure 38

Pressure Safety Devices 38

Manual Valves 40

Emergency Response 41


ThissectionprovidesinformationaboutthesafeoperationofyourtruckwiththeWestport HDSystem.

6.1 FuelsTheWestport HDSystemcontainsliquidnaturalgas(LNG),compressednaturalgas(CNG),lowpressurenaturalgasvapor(upto230psi),anddieselfuel.Thepresenceofthesecompoundsrequiresanunderstandingoftheirsafeuseandhandling.

Thefollowingsectiondescribestheliquidsandgasesyouwillencounterandthestepsyoushouldtaketoensuresafeoperationandhandling.MoreLNGinformation,suchastheMaterialsSafetyDataSheet(MSDS),isincludedinSection 11—LNG Properties and Handling.

6.1.1 Liquefied Natural Gas (LNG)Storedat-130°Cto-165°C,naturalgaswillnotigniteasliquidbutwilligniteasvapor.Ifreleasedtotheenvironment,LNGwillquicklyevaporateintonaturalgasvapor.Itisclear,odorless,andnon-toxicasaliquidoragas.

WARNING! LNG is a cryogenic (extremely cold) fluid. Avoid skin

contact with LNG and related plumbing. Freezing burns and lacerations could occur. Wear appropriate PPE when working around the LNG tank or plumbing.

6.1.2 Natural Gas (NG) Vapor and Compressed Natural Gas (CNG)

Whenmixedwithair,concentrationsof5–15%naturalgasisflammableandignitablebystaticdischarge.Itislighterthanair,odorless,andnon-toxic.Naturalgasisasimpleasphyxiant.CNGisnaturalgasstoredatextremelyhigh-pressures.

WARNING! Never smoke while fueling or expose natural gas to sparks or flames. Natural gas is flammable when

mixed with air.

WARNING! Natural gas is lighter than air and can accumulate in

enclosed spaces, such as under the hood or awnings. If there is an ignition source, an explosion could result.

Never allow the truck to vent in an enclosed space. Parking outside is mandatory.

WARNING! Do not stay in a natural gas vapor cloud. Natural gas

displaces oxygen and can cause asphyxiation.

WARNING! Natural gas is flammable when mixed with air, and is ignitable by static discharge. Ensure the grounding

straps are connected prior to fueling the vehicle.


6.1.3 DieselDieselfuelisstableatambientconditions,andboththeliquidandgasstatesareflammable.Thevaporisheavierthanair,hasadistinctivepetroleumodor,andcanignitewhenprovidedwithasourceofignition.Dieselisknowntocausesevereskinirritation,andisaharmfulorfatalifliquidisaspiratedintothelungs.

6.2 High PressureWARNING!

The Westport HD System contains high-pressure gas, liquid, and cryogenic fluids—even when the truck

is turned off. No unauthorized or untrained person should ever attempt maintenance or repairs on a


TheWestport HDSystemoperatesatpressuresupto330 bar(4,800psi).HighpressureispresentintheLNGtankandmostoftheCNGplumbing,evenaftertheengineisturnedoff.Thesystemisdesignedtosafelyhandlethesehighpressuresandisequippedwithpressuresafetydevices(seeSection 6.3—Pressure Safety Devicesformoreinformation).

6.3 Pressure Safety DevicesTheWestport HDSystemisequippedwithpressuresafetydevicesaslistedinthefollowingtable.

Table 3: Automatic relief valves and devices

Valve Location FunctionPrimary LNG tank pressure relief valve

Inside the vent manifold (see Figure N )

If tank pressure exceeds 16 bar (230 psi), valve opens automatically to relieve pressure through the vent stack.

Secondary LNG tank pressure relief valve

Below the LNG pump (see Figure N )

Backup relief valve in case of primary relief valve failure. Opens at 22 bar (315 psi), equipped with blow-off cap—may warn of primary malfunction.

Accumulator pressure relief valve

Near high-pressure gas filter (see Figure O )

Pressure activated valve—protects accumulator from over-pressure. Relief is set at 370 bar (5,400 psi).

Automatic tank shutoff valve

On tank interface panel; side depends on configuration (see Figure N )

Pressure activated valve—shuts off CNG flow from LNG tank if pressure drops below 26 bar (380 psi).

Accumulator pressure relief device

On the accumulator manifold (see Figure O )

Temperature activated device—protects accumulator from over-pressure.

In case of fire/heat exceeding 109 °C, discharges externally towards the ground.

Diesel pressure relief valve

On the FCM inside the engine bay

Protects engine from diesel over-pressure, returns relieved diesel fuel into diesel tank.


Figure N: LNG tank safety valves Figure O: High-pressure accumulator plumbing(other configurations possible)

Secondary LNG pressure relief valve (set at 22 bar / 315 psi)

Inspect presence of cap daily

Primary LNG tank pressure relief valve (inside vent manifold, set at 16 bar / 230 psi)

Automatic tank shut-off valve

High-pressure accumulator gas shut-

off (service only)

Accumulator pressure relief device—relieves at or

above 109 °C

Accumulator pressure relief valve 370 bar (5,400 psi)


6.4 Manual ValvesTheWestport HDSystemisequippedwithnumerousmanualvalves.Valvesmustbeoperatedonlybytrainedtechniciansandpersonnel.Thefollowingfigureandassociatedtableoutlinethelocationandfunctionofthevalves.

Figure P: LNG tank manual valves

Table 4: Manual valves

Valve / Location Function

Vent-to-station valveBelow and left of LNG pump* (see Figure P )

Hand turn valve. When open, valve allows vapor to flow from LNG tank through fill hose, and back to the fueling station. Valve is closed during normal truck operations and should only be open after filling hose or dedicated vent line is secured. Vent-to-station valve must be closed before and after fueling.

Vent-to-atmosphere valveBelow and right of the LNG pump* (see Figure P )

Hand turn valve. When open, valve allows flow of vapor from the LNG tank into the atmosphere via the vent stack. Valve must be closed during normal truck operation.

Liquid drain valveInside the tank shroud (see Figure P )

Valve requires a Westport service tool for operation. Drains LNG from the tank for service or maintenance. To be operated by trained service personnel only.

Accumulator shut-off valveLocated after the gas accumulator (see Figure O )

Quarter turn valve. Isolates high-pressure gas in the accumulator for service or maintenance. To be operated by trained service personnel only.

FCM vent valveInside the engine bay located on the FCM (see Figure E )

Hand operated valve. Vents gas system pressure for service or maintenance. To be operated by trained service personnel only.

* location indicated on tank shroud label

Vent-to-station valve

Vent-to-atmosphere

valveLiquid drain valve

(service only)


WARNING! Do not turn valves you are unfamiliar with.

Serious high-pressure blast or cryogenic burn injuries could occur.

WARNING! LNG is a cryogenic (extremely cold) fluid. Avoid

contact with the liquid and plumbing. Freezing burns and lacerations could occur. Wear appropriate PPE

when working around the LNG tank or plumbing.

CAUTION! The LNG tank vapor pressure can rise depending on

fuel temperature, and time since fueling.

6.5 Emergency ResponseDuetothepresenceofLNGandCNGon-board,additionalsafetyprecautionsmustbetakenwhenrespondingtoanemergencyinvolvingaWestport HDpoweredtruck.

Seetheinside front cover—Emergency SituationsandtheRecommended Emergency Response Procedure.

SeeSection 11.4—Sample LNG MSDS,formoreinformationonemergencymeasurewithrespecttoLNG.IfyouhaveanyfurtherquestionsorconcernspleasecontactWestportService(seeAppendix C—Contact Information).

Section 7 – Safe LNG Truck Fueling

Section 7 – Safe LNG Truck FuelingSection Contents

LNG Fueling Safety Equipment 43

Recommended Personal Protective Equipment (PPE) 43

Truck Equipment 43

LNG Fueling Basics 43

Basic Rules for LNG Fueling 44

Incident Reaction 45

Pre-Fueling 45

LNG Fueling Procedure 46

Venting 47

Venting to Station 48

Venting to Atmosphere 49

Minimizing Venting and Fuel Loss 49


FuelingofLNGtrucksishighlycontrolledandsafe.Thefollowingprecautionsminimizeharmintheeventofasafetyincident.Followtheprocedurestoensurethatthesafetyofthefuelingprocessismaintained.

7.1 LNG Fueling Safety EquipmentBelowisalistoftheminimumrecommendedpersonalprotectiveequipment(PPE)requiredforLNGfueling.ItisrecommendedthatthisequipmentiscarriedonboardaWestport HDpoweredtruckatalltimes.Checkwithyourfleetand/orLNGproviderastheymayhaveadditionalrequirements.

7.1.1 Recommended Personal Protective Equipment (PPE)

•Fullfaceshield

•Heavyleathergloveswithlongcuffs(cryogenicorweldingglovespreferred)

•Fire-retardantraincoatorapron

•Longpantsortrousers

•Closedtoeleathersafetyshoesorboots

NOTE: Theseareminimumrecommendations.Yourfuelingstationorfleetmayhavetheirownrequirements.

7.1.2 Truck Equipment•ABC-ratedmultipurposedrychemicalfireextinguisher—2.3 kg(5lbs)minimum*

•Emergencytrianglesorcones

•Flashlight(forpre-andpost-tripinspections)

* FormoreinformationonextinguishingfiresandotheremergenciesinvolvingLNGseeSection 11.4—Sample LNG MSDS.

7.2 LNG Fueling BasicsLNGfuelingreliesonthetransferofnaturalgasinliquidform.BecauseLNGispressurizedandcontainedinaclosedtanksystem,youcannotphysicallycheckthelevelofLNG(suchaslookingthroughthefillopeningofadieseltank).YoumustrelyontheWestportLNGDriverDisplayfuelgaugeandthestationdispensertodeterminetheamountofLNGpresentinyourtank.

Astheliquidpassesthroughthefuelinghoseandintothetank,someoftheliquidwarmsandconvertstovapor.ThisstatechangefromliquidtogasincreasesthevaporpressureinsidetheLNGtank.Thetankpressuregaugeindicatesthisvaporpressureanddoesnotindicatetheamountofliquidinsidethetank.TheWestport HDSystemreliesonlyontheliquidnaturalgas,notthevapor,unlikeothernaturalgasenginetechnologies.


WithvaryingLNGtankpressure,thefuelingprocedurecanchangeanddependslargelyonstationtypeandfuelcondition(temperatureandpressure).ThebasicrulesofLNGfuelingareconsistent.Detailedfuelingproceduresspecifictoyoursystemplumbing(suchasasingleversusmultipletanksystems),aswellastheparticularLNGstationusedatyournormalfuelinglocation,iscoveredinyourfuelingtraining.Thefollowingarebasicrules,whichmakefuelingeasierandshortenyourtimeatthepump.

7.2.1 Basic Rules for LNG Fueling1. Remembertofuelsafely.

•Followstationandtrucksafetyrules,andinspectyourequipmentbeforeuse.

•Befamiliarwiththeemergencyshut-down(ESD)buttonsincaseofanemergency.

•WearyourPPEandgroundthevehiclewithastationgroundingcable.

•Parkthetruckwithparkingbrakeon,engineoff,andkeyinthe[OFF]position.

•Checkthattherearenoignitionsourcesnearby(openflame,smoking,runningengines,etc.).

WARNING! Natural gas vapor is flammable when mixed with air, and is ignitable by static discharge. Ensure truck is

properly grounded during fueling. Do not smoke during fueling. Westport recommends not smoking while

operating a Westport HD powered truck.

2. VehicleLNGtankpressuremustbelessthanstationoutputpressure.

•Pressurecontrolisnotalwayspossible,asitdependsonfrequencyoftruckuseandfuelcondition.Factorssuchasplanningyourfuelingandventingbacktostationcanhelpwithpressurecontrol(seeSection 7.3—Minimizing Venting and Fuel Loss).

•Youcanstillfuelifthetankpressureexceedsthestationpressurebecausethestationisequippedwithapump,whichforcestheLNGintothetank;howeverthefillingprocessmaytakelongertocomplete.

•Minimizeventingtoatmosphere,asthisreleasesmethanegaswhichisharmfultotheenvironment.


3. UsecompressedairtocleananddrythefuelingnozzleandLNGtankreceptacle.

•Moistureinsidethenozzleandfuelingreceptaclescancausefuelingcomponentsandvalvestofreeze.

•Frozenmoistureinthenozzleandfuelreceptaclecancausedisconnectionproblemspost-fuelingandincreasedwear(seeSection 9—Diagnostics and Troubleshootingformoreinformation).

WARNING! LNG may spray during fueling as a result of poor

component fit and operation.

4. Knowyourtruck.

•Basedonyoursupervisedfillsandtraining,knowhowmuchfuelyoushouldbetakingonboard.

•RefertoTable 5: LNG tank volumesinSection 8.2.8—Usable LNG Tank SizestodeterminethemaximumamountofLNGatankcanhold.

NOTE: ThereadingontheLNGtankorfillpanelpressuregaugehasnocorrelationtoamountoffuelinthetank.

7.3 Incident ReactionYoumusthaveproperLNGfuelingtrainingtooperateanyLNGrefuelingstation.Trainingincludesinstructionsonwhattodoifthereisanemergencyoranincident.FollowthestepsoutlinedinyourspecificLNGEmergencyResponsePlan.Ifyouneedmoreinformation,contactyourlocalLNGstationrepresentative.

7.4 Pre-FuelingYoumusthaveproperLNGfuelingtrainingspecifictoyourLNGstation.ThistrainingdetailsthespecificprocesstofollowbeforefuelinganLNGtank.Usethefollowingpointsasaguidelinebeforefuelingyourtruck:

1. Verifythatanescaperouteisclearandunlockedforallfuelingpersonnel.

2. VerifylocationandreadinessofESDsandtheemergencyphone.

3. Inspectsafetyequipmentfordamage,readiness,andfit(fireextinguisherandPPE).

4. Visuallyinspectstationandtruckfuelsystempipingforleaksandbringanyleakstotheattentionofthestationprovider.

5. Neverleaveanopenvalveunattended.

6. Notifysitepersonnelifrequired.


7.5 LNG Fueling ProcedureWARNING!

The following procedure provides recommended guidelines only and does not replace proper training.

Due to the variety of fueling stations, you must receive training to your specific LNG fueling station.

1. Parkthetruckintheproperpositionforfueling.Thetransferhose,ventline,andgroundcablemustreachthetruckwithoutstretching.

2. Setthetruckbrakesandmakesurethetruckisoutofgear.

3. Turn[OFF]theignition.

4. Recordnecessarydatainthefuelinglogbookandthetrucklogbook.

5. PutonyourPPE.EnsurethatanyoneassistingyoualsowearsPPE.

6. AttachgroundclamptotheLNGtankorfillpanel.

7. Ifyouarefuelingatankthathasbeenemptiedforservicereasons,contactaWestport HDSystemtrainedtechnicianforadditionalfuelinginstructionsofa“hot”LNGtank.

8. Inspect,clean,anddrythefuelnozzle.Usepressurizedairtoremovedirtandicefromnozzleface.

9. RemovecaponLNGtank.Inspect,clean,anddryfuelconnector.Usecompressedairtoremovedirtandicefromconnectorface.

10. Connectfuelingnozzleanddedicatedventline(ifavailable)totheLNGremotefillpanel.

11. Performanynecessaryventingoffueltanks(seeSection 7.6—Ventingformoredetails).

12. Closemanualventvalves.

13. Startfuelingbypressingthestationstartbutton.

14. Thestationshouldstoponcethetankisfull.ConfirmthetankisfullbycheckingtheWestportLNGdriverdisplaywiththekeyinthe[ON]position.

15. Carefullydisconnectthefuelnozzleandventline.Installthedustcaponthefillhose,LNGtank,andventline.

16. Returnhose,ventline,andgroundclamptothefillingstation.

17. Finishrecordingnecessarydatainthefuelinglogbookandthetrucklogbook.

18. Removeandstowallsafetyequipment,beingcarefultobrushanyiceoffoftheglovesbeforeremovingthemfromyourhands.


WARNING! Natural gas vapor is flammable when mixed with air,

and is ignitable by static discharge. Ensure truck is properly grounded during fueling.

Do not smoke during fueling.

7.6 VentingAllLNGtanksmustventatsomepointtobeabletorefuel.LNGisacryogenicliquidandhasaverylowboilingpointof-130°Cto-165°Catatmosphericpressureandmustbestoredatverylowtemperatures.Theboilingpointisthetemperatureatwhichasubstancechangesfromaliquidtoagas.Forwaterthisisabout100°Catatmosphericpressure.LNGisconstantlychangingtoavaporastemperatureandpressureincreaseinsidethetank.

EachtankandLNGfillpanelisequippedwithapressuregaugewhichreadsthevaporpressure.Thegaugedoesnotindicateliquidlevel,onlyvaporpressure.Eachtankisalsoequippedwithapressurereliefvalve(seeSection 6.4—Pressure Safety Devices)whichrelievesat16bar(230psi).Themaximumpressureforfuelingdependsoneachstation,butgenerallyshouldnotexceed12bar(180psi).Followingaregeneralventingguidelines.

7.6.1 Venting to StationThepreferredventingmethodistousethevent-to-stationvalve.ThisvalveusestheLNGstationfilllineoradedicatedstationventlinetoreturntheexcessvaporbacktothestation.Thevent-to-stationvalveonlyworksiftheLNGfuelinghoseisattached.Youcannotfuelwhileventing.ThismethodworksonlyifthestationpressureislessthantheLNGtankpressure.Thefollowingstepsareguidelinesonly;youmustreceivepropertrainingforyourspecificstation.

1. CompleteSection 7.4—Pre-Fueling.

2. CompleteSteps1through11ofSection 7.5—LNG Fueling Procedure.

3. Openthevent-to-stationvalve(see“Figure Q: LNG tank shroud labels”).Youshouldhearthevaporventingthroughthefillhose/dedicatedventlineandseethehosebegintofrost.Donottouchfrostyhoseswithbarehands.

4. Monitorthetankpressureandwaituntilitdropstothedesiredlevel(LNGtankshouldequalizewiththeLNGstation).

5. Closethevent-to-stationvalve.

6. ContinuewithStep12ofSection 7.5—LNG Fueling Procedure.


Figure Q: LNG tank shroud labels

WARNING! Vent-to-station valve must be closed before fueling.

7.6.2 Venting to AtmosphereVentingtoatmosphereshouldonlybeperformedoutsideandonlywhenventingtostationisnotpossible.Ventingtoatmospherereleasesmethanewhichisharmfultotheenvironmentandpromotesfuelloss.UsethismethodifthestationpressureexceedstheLNGtankpressure.Thefollowingstepsareonlyaguideline,youmustreceivepropertrainingforyourspecificstation.

1. CompleteSection 7.4—Pre-Fueling.

2. CompleteSteps1though11ofSection 7.5—LNG Fueling Procedure.

3. Openthevent-to-atmospherevalve(see“Figure Q: LNG tank shroud labels”).Youshouldhearthevaporventingthroughtheventstackbehindthecab.

4. Monitorthetankpressureandwaituntilitdropstothedesiredlevel.

5. Closethevent-to-atmospherevalve.

6. ContinuewithStep12ofSection 7.5—LNG Fueling Procedure.


7.6.3 Minimizing Venting and Fuel LossMinimizingventingandfuellossisanimportantpartofoperatingyourWestport HDpoweredtruck.Withsomebasicguidelines,youcanreducefuellossandimprovethefuelingprocess.ContactyourlocalWestportServicerepresentativeifyouhavequestions(seeAppendix C—Contact Information).

Somegeneralsuggestionstominimizeventinginclude:

•Fuelrightbeforeashift,ratherthanthenightbefore.ThisminimizesthepressurebuildupfromLNGboil-offandkeepstheLNGcolderforlongerperiodsoftime.

• Ifventingmustoccur,useventingbacktostationratherthantoatmosphere.Ventingbacktostationwillre-collapsesomeofthevaporinsidethestation.Ventingtoatmospherereleasesmethanegas,whichisharmfultotheenvironmentandcausesfuelloss.

•Maximizeyourtrucksusewhenfuelled,byrunninglongertripsandminimizingidling.

•FrequentrefuelingcanhelpcondensesomeNGvaporbacktoLNG.

Section 8 – Westport HD System Maintenance and Care

Section 8 – Westport HD System Maintenance and CareSection Contents

Maintenance Schedules 51

Natural Gas Code Required Maintenance 54

Oil Drain Intervals 54

Recommended Fluids Specifications and Capacities 55

LNG Composition 55

LNG Cleanliness 55

Lubricating Oil 55

Coolant 55

LNG Pump / Steering Fluid Specifications 56

Diesel Fuel Specification 56

Biodiesel Fuel Use in the LNG System 56

Usable LNG Tank Sizes 57






8.1 Maintenance SchedulesThefollowingmaintenancetasksarerequiredtoensurethewarrantedperformanceoftheWestport HDSystem.

ThesemaintenancetasksandschedulesareonlyfortheWestport HDSystemanddonotreplacethemaintenancetasksrequiredbytheoriginalequipmentmanufacturer(OEM).PleaseseeOEMdocumentationforadditionalmaintenanceitemssuchasdaily/refuelingchecks,coolantflushes,hydraulicfluidchangeintervals,etc.

Exceptfordaily/refuelingchecks,allotherperiodicmaintenancemustbeperformedbyqualifiedWestport HDSystemtechniciansonly.

Thefollowingpagescanbeduplicated.

CAUTION! The use of fluids other than those approved by

Westport Service for use in the Westport HD System may void the system warranty.

ThemaintenanceschedulescontainedonthesepagesaresubjecttochangebyWestport.

ContactWestportService(seeAppendix C—Contact Information)todetermineifthereisauniquemaintenancescheduleforyourapplication.


Daily or Upon Refueling

Check operator’s report

Engine check

Drain all diesel fuel-water separators engine bay Check all engine drive belts Drain vent stack filter, if so equipped

Fluid check

Check engine oil, engine coolant, and hydraulic fluid levels

Check vehicle for diesel, hydraulic, and coolant leaks

Check hydraulic oil cooler for debris and/or damage

LNG System check

Check LNG System for loose or damaged components

Check LNG System for gas or diesel leaks Check LNG System for excessive frost Check gas detection monitor—alarms and lights Check LNG fuel level, tank pressure, and tank valve positions

Aftertreatment check

Check aftertreatment exhaust piping

Every 4 months

Conduct gas detection system function test1

Every 12 months 1,000 hours

50,000 km or 25,000 DLE whichever comes first

Conduct detailed gas leak check1 Conduct detailed diesel leak check Replace primary (low pressure) diesel filter2 Inspect (high-pressure) gas accumulator1,2 Conduct LNG tank visual inspection Drain vent stack filter2 1. or as per local regulations2. or as specified by OEM maintenance schedule

TheAftertreatmentDieselParticulateFilterintervalscanbeadjustedbasedonthetypeofengineoilthatitused.SeetheAftertreatmentCleaningIntervalstablebelowforcleaningintervals.

Oil Classification Kilometers Hours

CES 20081 480,000 6,750

CES 20078 360,000 6,750


Every 4,000 hours200,000 km

or 100,000 DLEwhichever comes first

Inspect all fluid hoses for leaks and deterioration1 Replace hydraulic spin-on filter1 Replace high-pressure natural gas filter1 Replace diesel pump drive belt Replace aftertreatment diesel dosing pump filter1 Replace vent stack filter1 1. Or as specified by OEM maintenance schedule



Clean DPF dosing injector LNG pump maintenance (single tank system)

Every 8,000 hours 400,000 km

or 200,000 DLE whichever comes first

LNG pump maintenance (dual tank system)



Injector maintenance LNG pump maintenance (triple tank system)

Westportrecommendsthemaintenancedescribedpreviouslybeperformedbeyondthewarrantyperiodandthroughoutthevehicle’slifetoensurepropersystemoperation.


8.1.1 Natural Gas Code Required MaintenanceTheownerisresponsibleforensuringtheirvehicleremainscompliantwithapplicablecodesregardingtheuseofnaturalgasinvehicles.

ToensurethatyourWestport HDpoweredtruckremainscompliantwithregulatorycodesoutlinedforNaturalGasVehicles,thefollowingtwochecksneedtobedone.

1. Thegasdetectionsystemneedstobefunctionallytested.RefertogasdetectionOEMdocumentationformoreinformation.

2. Thehigh-pressureaccumulatormustbeinspectedbyqualifiedpersonnel.RefertoOEMdocumentationformoreinformation.

ThesecheckshavebeenincludedintheWestport HDSystemMaintenanceSchedule.Ifyouhaveanyquestionsregardingcodecomplianceofyourvehiclecontactyourauthorizedrepaircenter(seeAppendix C—Contact Information).

8.1.2 Oil Drain IntervalsUsetheoilclassificationtablebelowtodeterminetheappropriateoildrainintervalforyourtruckapplication.

Toextendoildrainintervals,Westportrecommendsanoilmonitoringprogram.

Oil Classification CES 20081* CES 20078*

Severe Duty < 5.5 mpg (2.3 km/l) or > 80,000 lb (36,287 kg) GVW

24,000 km 32,000 km

or 14,000 DLE

Normal Duty 5.5–6.5 mpg (2.3–2.8 km/l) or 80,000 lb (36,287 kg) GVW

40,000 km 48,000 km

Light Duty > 6.5 mpg (2.8 km/l) or < 70,000 lb (31,751 kg) GVW

56,000 km 64,000 km

* The use of Centinel™ or any type of oil blending is prohibited. The use of a high-quality filter is mandatory. Refer to OEM documentation for filter part numbers. Engines equipped with an integrated Cummins Particulate Filter must operate on ultra-low sulfur diesel (15 ppm sulfur) fuel.


8.2 Recommended Fluids Specifications and Capacities

8.2.1 LNG CompositionTheWestport HDSystemrequiresthenaturalgascompositiontomeetthefollowingspecifications:

•CH4—Methane(minimum): 87.5%

•C2H6—Ethane(maximum): 6.5%

•C3H8andhigherhydrocarbons(maximum): 2.0%

•C6H14andhigherhydrocarbons(maximum): 0.0%

•Oxygen(maximum): 0.0%

• Inerts—CO2plusN2(maximum): 4.0%

WestportrecognizesthatLNGcompositionwillvarydependingonthesourceandsupplymethod.Ifyourfueldoesnotmeettheabovespecification,contactWestporttodiscuss.

8.2.2 LNG CleanlinessLNGdeliveredtotheLNGtankshouldbefilteredto5micronsnominal,10micronsabsolute.LNGtankfuelingreceptaclesmustbedriedwithcompressedairpriortofuelingtoavoidfreezingandcontaminationofthesystem.

8.2.3 Lubricating Oil WestportrecommendsfollowingstandardCumminsoiltypes,usuallytheuseofahigh-quality15W-40multiviscosityheavy-dutyengineoilthatmeetstherequirementsofCumminsEngineeringSpecificationCES20081/CJ-4orCES20078/CI-4.Special“break-in”enginelubricatingoilsarenotrecommendedforWestport HDSystemengines.

8.2.4 CoolantWestportrecommendsusingeithera50/50mixtureofgoodqualitywaterandfullyformulatedantifreeze,ora50/50premixedcoolant.Thefullyformulatedantifreezeorpremixedcoolantusedmustmeetbaseenginecoolantspecifications.Seebaseenginedocumentationforcoolanttestingand/orchangeintervals.TheapproximateextracapacityrequiredbytheWestport HDSystemoverthebaseengineis:

•3.37Lforasingletanksystem,

•5.52Lforadualtanksystem,and

•7.08Lforatripletanksystem.

WARNING! Do not remove the pressure cap from a hot engine.

Wait until coolant temperature is below 50 ºC before removing the pressure cap. Heated coolant spray or

steam can cause personal injury.


CAUTION! Damage to the Westport HD System can occur if

coolant mixture is incorrect. Ensure coolant mixture contains approved antifreeze.

8.2.5 LNG Pump / Steering Fluid SpecificationsTheWestport HDSystemandthepower-steeringassistsystemsharethehydraulicreservoirandcircuit.WestportrequiresthatATFDexronIIIoilisusedastheworkingfluidfortheLNGpump.

Inadditiontothebaseenginefluidcapacity,theLNGfuelsystemrequiresanadditionalamountofhydraulicfluidaslistedbelow(approximate):

•14Lforasingletanksystem,

•16Lforadualtanksystem,and

•22Lforathreetanksystem

8.2.6 Diesel Fuel SpecificationTheWestport HDSystemusesnaturalgasastheprimaryfuelalongwithdieselasanignitionsourceor“liquidsparkplug”.Theamountofdieselinjectedintothecylindervaries,withagreaterpercentageusedatidle.

TheADR80/03enginerequiresthatultra-lowsulfurdiesel(ULSD)mustbeused.Sulfurcontentofthedieselfuelcannotexceed15ppm.Failuretodosocanpermanentlydamageengineandaftertreatmentsystemswithinashortperiodoftime.Thisdamagecouldcausetheenginetobecomeinoperableandaffectthewarrantycoverageontheenginesystem.

CAUTION! Do not use diesel fuel blended with lubricating oil in engines equipped with an integrated Cummins

Particulate Filter.

WARNING! Serious engine damage and warranty non-compliance

can result by the use of incorrect diesel fuel.

WARNING! Fuel must be kept free of dirt and water. Dirt and water

can cause severe damage to the fuel system.

8.2.7 Biodiesel Fuel Use in the LNG SystemWestportdoesnotrecommendorendorsetheuseofbiodieselfuelintheWestport HDSystem,beyondtheuseofB5(5%biodiesel).However,theoperatorshouldnevermixbiodieselwithULSD.


Whiledieselisonlyusedinasmallportionofthecombustionprocess,thecombustioncharacteristicsofthedieselfuelarecriticalforwarrantedengineperformance.WestportcertifiesitsengineusingtheprescribedEPACertificationFuels.Westportdoesnotcertifyenginesonanyotherfuel.

Emissionwarrantiesarevoidedwiththeuseofnoncompliantfuels.

CAUTION! Mixing biodiesel with ULSD in any volume may

result in damaged engine components, and void existing warranties.

WARNING! Failures or damage to the Westport HD System (including the Westport HD GX engine and LNG

storage and delivery system) caused by fuels not certified for use in the Westport HD System are not warrantable failures and will not be covered under

the Westport warranties.

8.2.8 Usable LNG Tank SizesThefollowingtableoutlinestheusableLNGvolumethatcanbeexpectedfromthevarioussizesoftheLNGtanks.AllWestportLNGtankshaveadataplateaffixedtothetankthatclearlystatesthetankwaterequivalentvolume.TheusablevolumeofthetankissmallerthantheproductiontanksizeduetoasafetyvolumeandthemaximumsuctionleveloftheLNGpump.

Table 5: LNG tank volumes

Production Tank Size Approximate Usable Volumes

265 L (70 U.S. gallons) 208 L of LNG



Section 9 – Diagnostics and Troubleshooting

Section 9 – Diagnostics and TroubleshootingSection Contents

Frozen Valves 59

Leak at Tank Fuel Receptacle 59

Excessive “Engine Warming Up …” Message Time 59

Difficulty Fueling with LNG 60

Jump Starting your LNG Truck 60

Sweaty or Frosty LNG Tank / Low Fuel Efficiency 60


YourWestport HDpoweredtruckisequippedwiththeWestportLNGdriverdisplay,whichprovidesinformationaboutthestatusoftheLNGsystem.IfafaultoccurswiththeWestport HDSystem,anon-screenmessageandactivefaultcodesaredisplayed.Formoreinformationaboutthemessages,refertoSection 5.1—Westport LNG Driver Display.ThiscapabilityallowsamoreaccurateandtimelyrepairtimeofyourWestport HDpoweredtruck.

AfulllistoftroubleshootingcodesandserviceproceduresisavailableforqualifiedWestport HDSystemtechnicians.

9.1 Frozen ValvesBecauseLNGisextremelycold,mostofthetankplumbinggetsverycoldduringfueling.Theamountoffrostdependsonmoisturecontentintheairaswellastheamountofdewonthetankplumbing.Thefrostingcansometimescausehandoperatedvalvestobecomedifficulttoturnorfreezeinoneposition.Thiscanbeaninconvenience,butitdoesnotnecessarilyindicateafaultyvalve.Beforereportingafrozenvalvetoashop,tryto:

•Letthevalvethawnaturallyinambienttemperatureair;

•Dryoffvalveswithcompressedair(availableatanyLNGstation)priortofueling;or

• Ifavailable,pourwater(hotorcold)directlyontothevalvebody.

Never:

•Heatvalveswithanyopenflameorheatgun;

•Hitvalveswithobjectssuchasahammer;

•Forcevalvesopenorclosed—theymaybreak;or

•Usepliersorothertoolsonhandvalves.

9.2 Leak at Tank Fuel ReceptacleLeaksatthetankfuelreceptacleusuallyoccurifthesealonthestationreceptaclehasbeendamagedoriscoveredwithice.Onewaytopreventiceordebrisbuild-upistodryofftheinsideofthefuelingreceptacle(onboththetruckandtheLNGstation)usingcompressedair.Alwaysinspectthetrucknozzleaswellasthestationreceptaclebeforeuse,andreportanydamageortamperingtotheLNGstationproviderorlocalcertifiedWestportrepaircenter.

9.3 Excessive “Engine Warming Up …” Message Time

Ifyouarestartingacoldenginewherethecoolanthasnotsufficientlywarmed,youwillseethe“EngineWarmingUpMax6MPH(10KM/H)”messagedisplayedonthedriverdisplay.Thisusuallyindicatesthatthecoolanttemperatureisnothighenoughtowarmthehigh-pressuregasatthepumpandassuch,theLNGpumpistypicallydisabled(Xthroughthegas


pumpicon)becauseitistoocoldtooperate(“snowflake”belowgaspumpicon).

Thismessageisalsodisplayedifthehigh-pressureaccumulatorisnotfullycharged.Youcandrivethetruckwithoutloadaslongasyoudonotexceed6mph(10km/h).Analarmwillsoundifthespeedlimitisexceeded.Youcanspeeduptheenginewarm-uptimebyusingthecruisecontroltosettheengineonhighidle.Alwayscheckyourcoolantlevelduringyourpre-andpost-tripinspectionstoensureproperWestport HDSystemoperation.

9.4 Difficulty Fueling with LNGMostfuelingdifficultiesarisefromLNGtankpressurebeingtoohigh,orfromfuelingequipmentbeingtoowarm.Thiscanoccurwhenfuelinganewtank,oratankwhichhasbeenemptyforalongtime.Section 7.2—LNG Fueling Basicsoutlinesthegeneralguidelinesforeasyandsuccessfulfuelingprocedures.Remember:Youmusthaveproperfuelingtrainingonthespecificstationyouareusing.

9.5 Jump Starting your LNG TruckIfyouneedtojumpstartyourLNGtruck,theon-boardgasdetectorwillbedisabledandunabletodetectanaturalgasleak.

Remembernaturalgasvaporiscolorless,hasnosmell,canaccumulateunderhoods/awningsandcanbeignitedbysparkorstaticdischarge.

NotifyyourlocalcertifiedWestportrepaircentertoreceivefurtherinstructions.

9.6 Sweaty or Frosty LNG Tank / Low Fuel Efficiency

TheWestport HDSystemusesLNGastheprimaryfuelsource,whichmustbekeptatcryogenictemperatures.Tokeepthefuelcold,LNGtanksareinsulatedwithavacuumlayer.

Ifyouconsistentlynoticeexcessivefrostingorcondensation(sweat)onyourLNGtanks,yourtankvacuummayhavedegraded.

ApoorLNGtankvacuumcanalsobedetectedbyalossoffuelefficiencyand/ortheLNGtankpressurebuildsfasterthannormal.

Itisimportanttorecordtankpressures,andnoteLNGtankconditionaspartofyourpreandposttripinspections.Thesecheckshelpyoutounderstandwhatisnormalforyourvehicle.

ContactyourlocalcertifiedWestportrepaircenterifyoususpectapoorLNGtankvacuum.

Section 10 – Exhaust Aftertreatment

Section 10 – Exhaust AftertreatmentSection Contents

Exhaust Aftertreatment Considerations 63

Diesel Particulate Filter (DPF) 63

Section 10 – Exhaust Aftertreatment

10.1 Exhaust Aftertreatment Considerations

Westport HDpoweredtrucksareequippedwithanOEMintegratedCumminsDieselParticulateFilter(DPF)whichhasitsownoperationalandsafetyconsiderations.

10.1.1 Diesel Particulate Filter (DPF)PleaserefertothePACCAREngineAftertreatmentSystemsoperator’smanualandbaseengineowner’smanualformoreinformationontheDPFaftertreatmentsystem.

WARNING! Regeneration, as part of the exhaust

aftertreatment system, can cause exhaust gas and the exhaust system surfaces to get

hot enough to cause serious burns and ignite common materials. Refer to OEM documentation

for more information on associated hazards.

Section 11 – LNG Properties and Handling

Section 11 – LNG Properties and HandlingSection Contents

Physical Properties 65

Safety Hazards 65

First Aid 66

Sample LNG MSDS 66


TheprimaryfueloftheWestport HDSystemisLNG.Asacryogenicliquidwithflammablevapor,ithassomeparticularcharacteristicsandsafetyhazards.

11.1 Physical PropertiesLNGisaclearliquidthatislessdensethanwater.Itwillcauseseverefrostburnsifallowedtocontactskin.Itdoesnotsmellandboilsbetween-130°Cand-165°C.Naturalgaswillriseanddisperseinaironceithasvaporized.Whenmixedwithairinconcentrationof5–15%,naturalgasisflammableandcanbeignitedbystaticdischarge.

11.2 Safety HazardsWARNING!

LNG is a cryogenic (extremely cold) fluid. Avoid contact with LNG and related plumbing. Freezing

burns and lacerations could occur. Wear appropriate PPE when working around the LNG tank or plumbing

WARNING! Natural gas is lighter than air and can accumulate in enclosed spaces, such as under the hood or under awnings. If there is an ignition source an explosion

could result. Never allow the truck to vent in an enclosed space. Parking outside is mandatory.

WARNING! Natural gas is colorless and odorless. You must check the operation of the gas detection monitor

and listen for sounds of a leak. If you detect signs of a leak, see red or yellow lights, hear a gas alarm, or

cannot see the green power light on the detector, do NOT enter or operate the truck. Notify the shop from

outside the truck.

WARNING! Do not stay in a natural gas vapor cloud. Natural gas

displaces oxygen and can cause asphyxiation.

WARNING! Natural gas is flammable when mixed with air, and is

ignitable by static discharge. Ensure truck is properly grounded during fueling. Do not smoke during fueling. Westport recommends not smoking while operating a



11.3 First AidIfLNGcausesburnsontheskin:

•Removeanyclothingthatmayrestrictcirculationtothefrozenarea.Donotrubfrozenparts,astissuedamagemayresult.Obtainmedicalassistanceassoonaspossible.

•Whenpractical,placetheaffectedpartofthebodyinaslightlywarmbath.Thawingmayrequire15to60minutesandshouldbecontinueduntilthepaleblueoftheskinturnspink.

• Iffrozentissuehasthawedbeforemedicalattentionhasbeenadministered,covertheareawithdrysteriledressingandalarge,bulkyprotectivecovering.

11.4 Sample LNG MSDSMATERIAL SAFETY DATA SHEET

LIQUEFIED NATURAL GAS (MSDS #582)

Revision Date: April 7, 2008Supersedes Date: February 20, 2004

Section 1 – PRODUCT AND COMPANY IDENTIFICATION

Terasen Gas Inc. Company Phone: (604) 592-7629 16705 Fraser Highway Emergency Phone: (604) 946-4818 Surrey, BC V3S 2X7 Canada

Product Name: Liquefied Natural Gas

Material Use: Various

Manufacturer: Terasen Gas LNG Plant Supplier: Terasen Gas LNG Plant 7651 Hopcott Rd 7651 Hopcott Rd Delta, BC V4G 1B7 Delta, BC V4G 1B7 Canada Canada

WHMIS Class: A – Compressed Gas; B1 – Flammable and Combustible Material – Division 1 Flammable Gases

UN/PIN Number: 1972

TDG Classification: Class 2.1 Flammable Gases

Chemical Family: Hydrocarbon Liquid

Chemical Formula: CH4 (Methane)

Molecular Weight: 16.04 (Methane)

CAS Number: 74-82-8

Trade Names and Synonyms: Liquefied Methane


Section 2 – HAZARDS IDENTIFICATION

EMERGENCY OVERVIEW

Appearance/Odor: Odorless, colorless liquid. This product is not odorized.

Flammable: Very flammable after vaporization to gaseous phase.

Potential Health Effects: See Section 11 for more information

Potential Environmental Effects: See Section 12 for more information.

Likely Routes of Exposure: Eye and skin contact, acute inhalation

Acute - Eye, Skin and Inhalation: Liquid or cold gas contact with skin or eyes could cause freezing or severe cryogenic burns. After vaporisation, contact with burning gas may cause burns.

Chronic- Inhalation: None

Ingestion: None

Skin Adsorption: None

Section 3 – FIRST AID MEASURES

Skin Contact: Cryogenic burns. Remove constricting clothing. Do not thaw too rapidly. Transport to hospital immediately.

Eye Contact: Get medical attention immediately.

Inhalation: Move to fresh air. Give artificial respiration if breathing has stopped. Call a physician.

Ingestion: Unlikely route of exposure as this is a gas at normal room temperature and pressure.

General Advice: Use extreme care in handling due to high flammability and risk of cryogenic burns.

Section 4 – COMPOSITION / INFORMATION ON INGREDIENTS

Component CAS Number % by Wt. Exposure Limits(1)

Methane 74-82-8 95 Simple Asphyxiant Ethane 74-84-0 3 Simple Asphyxiant Propane 74-98-6 1 Simple Asphyxiant Nitrogen 7727-37-9 1 Simple Asphyxiant

(1) See Section 8 for additional exposure limit information for C1 to C4 Aliphatic Hydrocarbon Gases.

Section 5 – FIRE FIGHTING MEASURES

Flammability: Flammable gas

Suitable Extinguishing Media: Dry Chemical (Purple-K). To suppress or contain, use water fog or high expansion foam.

Unsuitable Extinguishing Media: Do not direct water spray directly at LNG pool; this will only increase rate of vaporization. Cold vapor is heavier than air and will not readily disperse until warmed up. High expansion foam may be used to help control the vaporization rate.

Products of Combustion: Carbon dioxide and carbon monoxide

Protection of Firefighters: Very flammable after vaporization to gaseous phase. Firefighters should wear self-contained breathing apparatus (SCBA) in case of oxygen deficient atmosphere. Use Combustible Gas Indicator to determine the extent of vapor cloud.

Sensitivity to Static Discharge: Ignitable by static discharge

Sensitivity to Mechanical Impact: None

Explosive Power: Not known


Section 6 – ACCIDENTAL RELEASE MEASURES

Personal Precautions: Use personal protection recommended in Section 8.

Environmental Precautions: Not applicable

Methods for Containment: Evacuate area for 2000 foot (600 m) radius. Stay out of vapor cloud.

Methods for Clean-Up: Wear all protective equipment recommended in Section 8. Eliminate source of ignition.

Other Information: Allow to vaporize and disperse to atmosphere.

In case of an emergency and no response at LNG plant, call SERVICE CENTER: 1 (800) 663-9911.

Section 7 – HANDLING AND STORAGE

Handling: To be handled by trained personnel only, using equipment specifically designed for LNG, and following approved operating procedures.

Storage: Store only in vessels designed for LNG storage, and follow approved operating procedures.

Section 8 – EXPOSURE CONTROLS / PERSONAL PROTECTION

Exposure Limits: Simple asphyxiant - Maintain 19.5% oxygen level (below 19.5% oxygen is considered to be oxygen deficient).

Constituent ACGIH (8-hour) TWA WorkSafeBC (8-hour TWA) Methane 1000 ppm 1000 ppm Ethane 1000 ppm 1000 ppm Propane 1000 ppm 1000 ppm Nitrogen None listed None listed

Personal Protection Equipment: Ensure use of proper PPE at all times when handling this product.

Eye/face: Face shield with other eye protection (safety glasses)

Skin: Insulated gloves, safety work boots, Nomex coveralls.

Respiratory: Supplied air respiratory protection to be used (airline or self- contained breathing apparatus) in cases of oxygen deficient atmospheres.

Other Considerations: Use extreme care in handling due to high flammability and risk of cryogenic burns.

Engineering Controls: Provide electrical ground for all parts of handling system. Provide adequate ventilation to maintain more than 19.5% oxygen, less than 1% methane (20% of the lower explosive limit). Use of CGI is mandatory since product is odorless.

Section 9 – PHYSICAL AND CHEMICAL PROPERTIES

Color: Colorless pH: Not applicableOdor: Odorless Freezing Point (˚C): -182.5Odor Threshold (ppm): Not available Boiling Point (˚C): -161.5Physical State: Liquid Flash Point (˚C): -187.8Evaporation Rate: RapidFlammability (solid, gas): Flammable gasLower Explosion Limit: 5% (by volume, gas phase)Upper Explosion Limit: 15% (by volume, gas phase)Vapor Pressure: Container ratingVapor Density: > 1 @ -112 ˚C (air = 1)Specific Gravity: 0.45 (water = 1)Solubility in Water (20 ˚C): 24.4 parts per millions (wt)Partition Coefficient: Octanol/water – 1.09 LogKOWAuto Ignition Temperature: 537 ˚C (gas phase)Percent Volatile (by volume): 99%Density (g/ml): 0.45 @ Boiling Point

Section 10 – STABILITY AND REACTIVITY

Chemical Stability: YesCompatible Materials: Air, oxidizers, halidesHazardous Decomposition Products: None knownReactivity (and under what conditions): None known


Section 11 – TOXICOLOGICAL INFORMATION

LD50: Not availableLC50: Not availableAcute Effects: Liquid or cold gas contact with skin or eyes could cause freezing or severe cryogenic burns. After vaporization, contact with burning gas may cause burns.Chronic Effects: Not availableCarcinogenicity: Not considered carcinogenic by IARC, NTP, ACGIH or OSHA.Reproductive Effects: Not availableTeratogenicity: Not availableMutagenicity: Not availableIrritant: Not availableSensitizer: Not availableSynergistic Effects: Not available

Section 12 – ECOLOGICAL INFORMATION

Ecotoxicity: Not applicablePersistence / Degradability: Not applicableBioaccumulation / Accumulation: Not applicable

Section 13 – DISPOSAL CONSIDERATIONS

Disposal: Allow to vaporize and disperse to the atmosphere.

Section 14 – TRANSPORTATION INFORMATION

TDG Classification: 2.1 Flammable GasesUN/PIN Number: 1972Shipping Name: Methane, Refrigerated Liquid, or Natural Gas, Refrigerated Liquid with high methane contentSpecial Shipping Information: Transport only in shipping container designed for LNG and follow approved operating procedures.

Section 15 – REGULATORY INFORMATION

DSL (Canada): This product is on the DSL list.WHMIS Class: A – Compressed Gas; B1 – Flammable and Combustible Material – Division 1 Flammable Gases

Section 16 – OTHER INFORMATION

National Fire Protection Association (NFPA 704) Ratings:

Health 2 LEGEND 0 = minimal hazard Flammability 4 1 = slight hazard Instability 0 2 = moderate hazard (For methane from NFPA 325) 3 = severe hazard 4 = extreme hazard

Prepared by: AMEC Earth & Environmental Phone Number: (604) 294-3811 Occupational Hygiene Preparation Date: April 7, 2008 and Safety Group

Additional Information and Comments: This MSDS has been updated from a 9 section MSDS (2004-02-20) to a 16 section MSDS on 2008-03-10. All sections and the order that which they appear have been changed as per American National Standard – For Hazardous Industrial Chemicals – Material Safety Data Sheets Preparation (ANSI Z400.1-2004).

New text has been added in Section 8: Exposure Guidelines, WorkSafeBC and ACGIH exposure limits for methane, ethane, and propane (WorkSafeBC Occupational Health and Safety Regulation (OHSR), Guidelines Part 5, Table of Exposure Limits for Chemical and Biological Substances and ACGIH TLVs and BEI’s, Threshold Limit Values for Chemical Substances and Physical Agents & Biological Exposure Indices, 2007, respectively).

The information contained in this document applies to this specific material as supplied. It may not be valid for this material if it is used in combination with any other materials. It is the user’s responsibility to satisfy oneself as to the suitability and completeness of this information for their own particular use.

Information Sources: Various

Appendix A – Daily Log Sheet (Sample)

Appendix A – Daily Log Sheet (Sample)Thisappendixcontainsasampledailylogsheetthatyoucanduplicate.

Appendix A – Daily Log Sheet (Sample)

Name: Date:

Truck/Tractor No.: Odometer:

Pre-trip Inspection of Westport HD System

Before entering cab:

� Check gas detection monitor is powered� Check gas detection monitor is not in alarm

After entering cab:

� Check gas detection monitor operation by pushing [TEST] button� Check diesel and LNG fuel levels

Inside engine compartment:

� Check for leaks, damage or tampering� Check hoses and fittings� Drain all diesel fuel-water separators� Drain vent stack filter� Inspect high-pressure diesel pump and belt� Inspect hydraulic pump� Inspect FCM� Check engine oil levels� Check engine coolant levels� Check hydraulic levels

Outside engine compartment:

� Check gas filter located on frame rail for leaks or damage� Check LNG System (tanks, valves, plumbing) for frost or hissing� Check for presence of secondary relief valve cap inside all

LNG tank(s)� Check vent-to-station valve is closed� Check the vent stack is not venting excessively gas� Check hydraulic oil cooler is unblocked and free of debris� Check aftertreatment exhaust piping

System pressure:

Tank 1 (Tank 2) (Tank 3)

Fueling

LNG: Quantity added Odometer reading after fill

� Check Vent-to-Station valve is closed

LNG level(s) after fill:


Diesel: Quantity added Odometer reading after fill

Post-trip Inspection of Westport HD System

Check LNG system:

� No gas leaks (no frost, hissing sound, or alarm)� No hydraulic or coolant leaks� No leaks in engine compartment� Ensure Westport HD System components are securely mounted.� Check for presence of secondary relief valve cap inside all

LNG tank(s)

System pressure:


Notes:

Appendix B – Towing and Recovery

Appendix B – Towing and RecoveryIngeneral,non-accidentrelatedtowingandrecoveryoperationsonWestport HDpoweredtrucksareidenticaltoconventionaldieseltrucks.Thefollowingadditionalprecautionsandlimitationsapply:

1. Ensurethatthegasdetectionmonitorisnotindicatingyelloworredbeforecommencingtowing/recovery.

2. Absolutelydo not smokeinoraroundtheWestport HDpoweredtruckduringrecoveryoperations.Naturalgasvaporishighlyflammable.

3. Donottouchanytruckhosesorlinesthatappearfrosty.LNGpipingisverycoldandcancausesevereburnsorfrostbitewhenincontactwithskin.

4. Bealertforvaporcloudsnearthegroundorpoolsofliquidform,indicatingaLNGleak.CeaserecoveryimmediatelyandcontactyourlocalcertifiedWestportrepaircenterand/oremergencyresponseservices.

5. OnlyrecoverimmobilizedtrucktoapprovedWestport HDSystemrepairfacilities.DonotattemptmaintenanceontheWestport HDSystem.

6. ImmobilizedWestport HDpoweredtrucksmust notbedroppedoff/storedindoorsattherepairshopovernight.Notifyrepairshoppersonnelofthedrop,andthatLNGispresentinthetruck.

WARNING! Your Westport HD powered truck must park outside. Never allow the truck to vent or leak in an enclosed

space. Natural gas will rise and collect in areas where there may be an ignition source.

An explosion could result.





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Appendix C – Contact Information

Appendix C – Contact Information

Corporate OfficeWestportPowerInc.

101–1750West75thAvenue

Vancouver,B.C.

CanadaV6P6G2

phone: 1-604-718-2000

fax: 1-604-718-2001

www.westport.com

Westport HD Service Department

[email protected],partsordering,andwarrantyinformationvisit:

service.westport-hd.com

Westport HD ADR80/03 LNG System Operator’s Manual P/N: 10017071

Revision: 00 Date: October 2010

adr80/03 lng system operator's manual

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