Field Service Bulletin
Emcara PRD Water Entry
on Side Mount CNG Systems

ENP-374, Rev. A
May 6, 2015

1. Introduction

Figure 1 Left: Emcara area PRD, Agility Fuel Systems 25600418, 256000417 and others.
Right: Emcara PRD installed in a side mount system. The pre-installed tube contains a
temperature sensitive wire trigger.

Figure 2 Left: PRD vent stack for a side mount system. Right: Vent tube and transition to
vent hose. A weep hole (yellow arrow) allows water entry when the vehicle is pressure
washed or exposed to extremely heavy rain.
High pressure washing systems and heavy rain may be forcing water into area pressure relief
devices (PRDs) via the vent tube drainage hole. Water inside the PRD may freeze and expand,
potentially causing the PRD components to malfunction and the PRD to vent.
To prevent water entry and PRD failure, the PRD vent tube routing has been re-shaped.
As part of this procedure, new re-shaped vent tubes and PRD exit tubing (vent stack) must be
installed. In addition, as a precaution, the PRDs in affected vehicles must be removed and
replaced.
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2. Affected Units
This procedure applies to the initial build of Gen4 (aluminum cover) side mount systems for Volvo
chassis vehicles. Affected customers/fleets are being notified. Behind the cab (BTC) systems, roof
mount and other configurations are not affected by this water entry issue.

3. Tools, Materials and Required Parts
1.
2.
3.
4.
5.

Common hand tools
Nickel-teflon tape
Leak detection fluid
O-ring lubricant, high pressure, silicone-based such as Parker Super-0-Lube
For each vehicle:
a. One (1) Area PRD, Agility Fuel Systems part number will vary depending on the
vehicle and where the system mounts (left or right).
b. One (1) PRD vent stack, as appropriate.
c. One (1) Formed tube, PRD to bulkhead.
d. A kit/part number matrix is attached at the end of this bulletin.

4. Procedure
DANGER

Since PRDs are connected directly to the CNG cylinders, the fuel tubes are always
under full and constant high pressure. You must defuel the cylinders before
performing work on the PRDs.
1. Depressurize and de-fuel the system.
2. To gain access to the PRD, remove the 3/8-16 bolts on the bottom cover, as shown in
Figure 3.
SYSTEM TILTED TO SHOW
SYSTEM BOTTOM COVER

Figure 3 Working under the vehicle, remove the bottom cover to gain access to the PRD and
vent tube. (Left side mount system with FMM shown.)

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Figure 4 The yellow arrow points to the vent tube to be removed.
3. Remove the two fuel tubes going to the PRD and remove the three bolts that secure the
PRD to the mounting bracket.
4. Remove the PRD trigger tube mounting clamps. The trigger tube is part of the PRD and
must be removed and replaced with the new PRD.
Note: The lower rear heat shield bolts may be removed to access the trigger tube and
clamps.
5. Remove the PRD – to be safe, we must assume the PRD has been compromised because
of possible moisture entry.
6. Remove both ends of the PRD vent hose from the PRD as shown in Figure 5.

PRD vent hose
connected to the
bulkhead connector on
the rail mount system

Figure 5 Disconnect the PRD vent hose from the PRD vent connection at the bulkhead
connector at the rear of the system.
7. Use compressed air to blow out any moisture and debris from the PRD flex hose or hoses
as shown in Figure 6. The hose does not have to be removed from the vehicle.

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Figure 6 Disconnect the flex hose from the PRD and blow out moisture and debris.

8. Install the new PRD onto its mounting bracket.
PRD location for
non-FMM side
mount systems

PRD location for
left side mount
(behind ECU)

New PRD vent
tube for nonFMM rail mount
systems

New PRD vent
tube for FMM
rail mount
systems

Figure 7 New shape PRD vent tubes eliminate water entry and collection. Left: Side mount
systems with a fuel management module, Right: Side mount systems without FMM.

NOTE: Actual tube shapes will vary depending on system.

9. Attach the new vent tube to the PRD as shown in Figure 7.
10. Re-attach the flex hose at the bulkhead connector, and attach the vent tube stack. Make
sure the UV-protected cap is in place at the vent tube exit.
11. Re-fuel the system, test for leaks, and repair as needed.
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12. When the system is leak-free, the vehicle can be returned for service.

5. Warranty Information
1. This procedure is covered under warranty. Return the defective parts using the CRN
procedure in the Warranty Manual, ENP-067, Section 3.6:
a. All removed components must be identified with the CRN.
b. The servicing dealer will have 15 days to return the defective part to Agility. The
package and label containing the returned part(s) must be clearly marked with the
CRN. Return parts may be shipped UPS collect to:
Agility Fuel Systems
Attn: Warranty Processing – CRN ____________
1815 Carnegie Ave
Santa Ana, CA 92705 USA
c. If requested parts are not returned to Agility per the above listed guidelines, the
dealer will be charged back for all parts contained within each claim or shipped to
the dealer by Agility.
2. Standard repair time (SRT) for this procedure is 2.75 hours.
If you have any questions, contact Agility Fuel Systems Product Support at 949-267-7745 or
[email protected].
Agility Fuel Systems, Product Support, 1815 Carnegie Ave., Santa Ana, CA 92705 USA
Warning Message Used in this Bulletin

DANGER
Personal injury or death may occur if procedures are not followed.
Proprietary Statement
The information provided within this document is proprietary and confidential. All prior versions,
including updates and revisions forwarded separately, are proprietary. The information provided by
Agility Fuel Systems to its customers and clients is solely for the use of those customers and
clients. No portion of this manual may be reproduced or distributed without express written consent
of Agility Fuel Systems. Agility Fuel Systems reserves the right to utilize the intellectual property
contained within this publication as content for any other publication produced by Agility Fuel
Systems.
Trademark Notice
Agility Fuel Systems® is a registered trademark of Agility Fuel Systems. Drop-N-Go™ is a
trademark of Agility Fuel Systems. Trademarks of other manufacturers are the property of their
respective companies.
Revision

Description

Author

Approved By

Date

--

Initial Release
Added system-part
number matrix and
drawings

W. Yoshida

A. Bhakta

4/6/15

W. Yoshida

A. Bhakta

5/6/15

A

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PRD Water Entry Repair Kit: One Kit Needed for Each Side Mount System

1
2

REPAIR KIT PART
NUMBER
22999402
22999404

FOR SIDE
MOUNT SYSTEM
22999700
22999600

3

24960402**

24960800

4

24960404

24980600

4

24960404

24980611

5

24980402**

24980500

6

24980404

24980711

7
8

24990401
24990402

24990722
24990601

9

25789402

25789600

10

25789403

25789700

Ref. No.

SYSTEM DESCRIPTION
45 DGE Aluminum Cover
45 DGE Aluminum Cover
Right side mount system without
FMM
45 DGE Aluminum Cover (No
FMM)
40 DGE One Piece Aluminum
Cover, No FMM
Left side system with FMM
40 DGE One Piece Aluminum
Cover, with FMM
45 DGE Aluminum Cover
45 DGE Aluminum Covers
40 DGE One Piece Aluminum
Cover, No FMM
40 DGE One with FMM

**NOTE:
Kits 24960402 and 24980402 require one (1) 9/16-18 SAE O-ring rated for -40°F to 225°F,
NBR/Buna, N1470-70, Part number 10500014 to seal the live side of the PRD.
The other kits include the O-ring.

The kits contain:
a. One (1) Area PRD, Agility Fuel Systems part number will vary depending on the vehicle and
where the system mounts (left or right).
b. One (1) PRD vent stack, as appropriate.
c. One (1) Formed tube, PRD to bulkhead.

6. Attachments: Repair Kit Drawings

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BILL OF MATERIALS
ITEM QTY

PART NUMBER

DESCRIPTION

1

2

10200250

Fitting, Tube, Nut and Ferrule Set, 1/2in Tube OD,

2

1

10240099

Fitting, JIC, Sleeve, -8 JIC, SS

3

1

10240248

Fitting, JIC, Swivel Nut, -8 Female JIC, 1/2in Tub

4

1

10500014

O-Ring, 3-908, 9/16-18 SAE, -40 To 225F, NBR/Buna,

5

1

10702028

Cap, 1/2in, UV Protected, Black

6

1

22999401

Tube, Formed, 1/2 in X .035 in, PRD To Bulkhead

7

1

24990400

Emcara PRD, 1/4 in x 7 ft, 10300661

8

1

25700419

Tube - Formed, 1/2 in. x 0.035in, Vent Hose to Ven

8

7
5
6

3

2

4

1

2651
MY 4/21/15 INITIAL RELEASE
ECN# REV BY DATE
TOLERANCES
UNLESS
OTHERWISE
SPECIFIED

NOTES:
1. KIT TO BE USED IN 22999700 SYSTEMS.
2. REFER TO ENP-374 FOR INSTALLATION INSTRUCTIONS.

SCALE 0.300

.XXX
.031"
.XX
.063"
.X
.125"
1
Hole dia +/-0.016

DESCRIPTION

Kit, PRD Vent Tube Assembly
Date:
Drawn:
Checked:
Approved:

Apr-06-15
MY
ATG
ATG

Scale:

AS NOTED

Dwg No.

Sheet:

22999402

This drawing and the designs depicted therein are the property of Agility Fuel Systems and we are covered by issued and/or pendingU.S. and foreign patents.
This material is provided to you subject to the condition that it shall not be reproduced, copied, disclosed to other vendors or manufacturers of similar
articles, lent or otherwise disposed of, directly or indirectly. It shall not be used tofurnish any information for the making of drawings, prints or
apparatus, or parts therefore, except where otherwise specifically provided for by contract with Agility Fuel Systems or its subsidiaries.

1 of 1
Rev.

-

BILL OF MATERIALS
ITEM QTY

PART NUMBER

DESCRIPTION

1

2

10200250

Fitting, Tube, Nut and Ferrule Set, 1/2in Tube OD,

2

1

10240099

Fitting, JIC, Sleeve, -8 JIC, SS

3

1

10240248

Fitting, JIC, Swivel Nut, -8 Female JIC, 1/2in Tub

4

1

10500014

O-Ring, 3-908, 9/16-18 SAE, -40 To 225F, NBR/Buna,

5

1

10702028

Cap, 1/2in, UV Protected, Black

6

1

22999403

Tube, Formed, 1/2 in X .035 in, PRD To Bulkhead

7

1

24990400

Emcara PRD, 1/4 in x 7 ft, 10300661

8

1

25700419

Tube - Formed, 1/2 in. x 0.035in, Vent Hose to Ven

8

7

5

3

2
4

6

1
2651
MY 4/21/15 INITIAL RELEASE
ECN# REV BY DATE
TOLERANCES
UNLESS
OTHERWISE
SPECIFIED

NOTES:
1. KIT TO BE USED IN 22999600 SYSTEMS.
2. REFER TO ENP-374 FOR INSTALLATION INSTRUCTIONS.

.XXX
.031"
.XX
.063"
.X
.125"
1
Hole dia +/-0.016

SCALE 0.300

DESCRIPTION

Kit, PRD Vent Tube Assembly
Date:
Drawn:
Checked:
Approved:

Apr-06-15
MY
ATG
ATG