ROUSH Blue Bird Vision Propane User manual
Blue Bird Vision Propane
Gen 4 Propane, 6.8L Ford V10
Service and Diagnostic Manual
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Gen 4 Blue Bird Vision Propane
Fuel System (6.8L V10)
SERVICE AND DIAGNOSTIC MANUAL
P19BB-01B001-AK
Revision History
-AC Updates 10/2019
-AD 06/2020
-AE Updated wire drawings 11/2020
-AE.1 Added P1450 12/2020
-AE.2 Added Evap Content 01/2021
-AE.3 Updated Pinpoint Test I 01/2021
-AF Added Pinpoint Test S 03/2021
-AG Minor updates 09/2021
-AH Updated Pinpoint Test S 09/2021
-AI Updated Fuel Tank Removal
10/2021
-AJ 12/2021
-AK 04/2022
All Rights Reserved.
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ROUSH CleanTech Gen 4 Blue Bird Vision Propane
Service and Diagnosc Manual
6.8L Gen 4 Blue Bird Vision Propane Service and Diagnosc Manual
Propane Flare.................................. 12
........................... 12
.................................. 12
PREPARATION FOR FUEL SYSTEM SERVICE .............. 12
........................... 12
................ 13
.................... 14
.................. 15
..................... 15
................... 16
FUEL SYSTEM SERVICE COMPONENTS AND PROCEDURES. 16
.............. 17
Tank Cover Plate ............................... 18
Tank Bleeder Valve/Liquid Level Gauge ............ 18
Tank Supply Valve Assembly ..................... 19
Removal ...................................... 19
Tank Return Valve Assembly ..................... 20
..... 21
Tank Pressure Relief Valve (PRV) .................. 22
Fill Filter ...................................... 22
Supply Line Filter ............................... 23
............................. 23
Fuel Pump Assembly ............................ 24
Fuel Level Sender (FLS) Twinsight ................. 25
Gateway Module ............................... 27
Solenoid Coils ................................. 27
Fuel Rail Pressure Control Module (FRPCM) and FRPCM
Bleed Port..................................... 28
Fuel Rails...................................... 29
TORQUE CHART .................................... 30
SYSTEM MAINTENANCE ............................. 31
................... 31
Fuel Tank...................................... 31
FAQs ............................................. 31
....................................... 31
Fueling ....................................... 31
....................................... 32
.................................. 32
Refueling. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
................................... 32
...................... 32
....................... 33
MAINTENANCE AND SPECIFICATIONS.................. 34
.... 34
FOREWARD ....................................... 1
CONTACTING ROUSH CLEANTECH .................... 1
.................................... 1
For Training.................................... 1
................................ 1
.............. 1
UPDATES.......................................... 1
REFERENCE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
...................... 2
............................... 2
IMPORTANT SAFETY INFORMATION ................... 3
................................. 3
Propane Flammability .......................... 3
Propane Vapor ................................. 3
Fuel Lines ..................................... 3
NFPA 58 Guidelines ............................. 3
....................................... 3
IMPORTANT WARNINGS............................. 3
Training....................................... 3
.................. 3
Tank Filling .................................... 3
Working on Tank Components .................... 3
.............................. 3
INTRODUCTION .................................... 4
Propane ...................................... 4
... 4
...................................... 4
.............. 4
SAFETY INFORMATION .............................. 4
................ 5
............. 5
................ 5
.................................... 5
General Propane Refueling. . . . . . . . . . . . . . . . . . . . . . . 5
......................... 6
....................... 7
...... 7
Requirements to Start .......................... 7
Blue Bird Vision Propane Fuel Rails ................ 8
Blue Bird Vision Propane Fuel Tanks ............... 9
.. 10
.... 11
SPECIAL TOOLS .................................... 12
.. 12
.................... 12
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ROUSH CleanTech Gen 4 Blue Bird Vision Propane
Service and Diagnosc Manual
6.8L Gen 4 Blue Bird Vision Propane Service and Diagnosc Manual
...................... 34
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............................. 35
...................... 35
............... 36
............... 37
............... 38
DIAGNOSTIC TROUBLE CODES ........................ 39
............... 39
............... 39
DIAGNOSTIC TROUBLE CODES EXPLAINED.............. 40
. 40
...... 40
... 40
...................................... 41
41
P0148 — Fuel Delivery Error ..................... 41
................................... 41
................................... 42
.................................. 42
... 42
.. 43
....... 43
.......... 43
...... 43
...... 44
Low .......................................... 44
High.......................................... 44
........................ 45
Low .......................................... 45
High.......................................... 45
....................... 46
Open ......................................... 46
.................................. 46
.................................. 46
................................ 47
..... 47
. 47
.......... 48
.................................. 48
... 48
... 49
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..... 49
. 50
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...... 51
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52
52
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.............. 53
....... 53
...................................... 53
............. 54
........... 54
Module ....................................... 54
Module A/B ................................... 55
.......... 55
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ROUSH CleanTech Gen 4 Blue Bird Vision Propane
Service and Diagnosc Manual
6.8L Gen 4 Blue Bird Vision Propane Service and Diagnosc Manual
.......... 55
DIAGNOSTICS AND PINPOINT TESTS ................... 56
Pinpoint Test A: No Fill .......................... 57
Pinpoint Test B: Slow Fill ......................... 58
Pinpoint Test C: OPD Test ........................ 59
Pinpoint Test D: Engine Does Not Crank ............ 60
............ 61
Fuel Pressure Drop ............................. 63
...... 65
......... 66
Pinpoint Test I: Fuel System Fails to Bleed........... 67
....... 68
............ 69
Pinpoint Test L: Fuel Rail Pressure Control Module
........................ 70
........................... 71
........................................ 72
................................. 73
..... 74
........................................ 75
..................................... 77
.... 79
................................... 81
................... 81
Tank Temperature Pressure Chart ................. 81
.............................. 82
ROUSH CleanTech Gen 4 Blue Bird Vision Propane
Service and Diagnosc Manual, 6.8L Ford Engine
16.8L Gen 4 Blue Bird Vision Propane Service and Diagnosc Manual
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FOREWARD
Propane operators guide for the year of your bus. For base engine or
CONTACTING ROUSH CLEANTECH
For Service
For Training
www.
the main page.
For Publicaons
Team at .
For the ROUSH Diagnosc Tool (RDT)
ROUSH.
UPDATES
•
•
•
•
•
ROUSH CleanTech Gen 4 Blue Bird Vision Propane
Service and Diagnosc Manual, 6.8L Ford Engine
26.8L Gen 4 Blue Bird Vision Propane Service and Diagnosc Manual
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Acronym or
Abbreviaon Descripon
MIL
MY Model Year
NFPA
NFPA 58 Liquid Petroleum Gas Code from the NFPA
Nm Newton Meter
OASIS
OBD
OEM
OPD
OTIS
PCM Powertrain Control Module
PERC
PID
PRV Pressure Relief Valve
RDT
VECI
WC
REFERENCE
Commonly Used Acronyms
Acronym or
Abbreviaon Descripon
BS Bleed Solenoid
CAN Controller Area Network
DTC
DTE
ECU Engine Control Unit
EFPR
EGR
EPA
EVAP
FPCM Fuel Pump Control Module
FCS Flow Control Solenoid
FPTS Fuel Pressure and Temperature Sensor
FRP Fuel Rail Pressure
FRPCM Fuel Rail Pressure Control Module
GWM Gateway Module
IPTS Integrated Pressure Temperature Sensor
KOEO
KOER Key On Engine Running
LPA Liquid Petroleum Autogas
Engine Direcons
Engine Front
Engine Rear
Engine Le�
Engine Right
ROUSH CleanTech Gen 4 Blue Bird Vision Propane
Service and Diagnosc Manual, 6.8L Ford Engine
36.8L Gen 4 Blue Bird Vision Propane Service and Diagnosc Manual
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IMPORTANT WARNINGS
Training
and/or death.
Service and System Modicaon
Tank Filling
Working on Tank Components
important to verify that there is not any pressure remaining inside
always be the one to verify it is empty and this should be done right
before removing or
Tank Maintenance
IMPORTANT SAFETY INFORMATION
Propane Facts
air it will immediately seek the lowest point in the area where it
is released.
Propane Flammability
when working with propane. Failure to heed this danger may result
Propane Vapor
Fuel Lines
NFPA 58 Guidelines
Always follow all NFPA 58 guidelines. When working on the propane
Baery
death.
ALERT MESSAGES
will appear in this manual to remind all personnel working with or around propane of the safety risks of working with propane.
ROUSH CleanTech Gen 4 Blue Bird Vision Propane
Service and Diagnosc Manual, 6.8L Ford Engine
46.8L Gen 4 Blue Bird Vision Propane Service and Diagnosc Manual
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level the dash fuel gauge will read full. The pressure in the tank is
Maintenance
ROUSH CleanTech Customer Success
SAFETY INFORMATION
INTRODUCTION
propane fuel system installed on the Ford 6.8L V10 engine. For any
Propane
observed when working on or around propane-powered equipment
or storage tanks.
web address is .
ROUSH CleanTech Propane Fuel System Overview
to the engine in a vapor
liquid propane into the engine.
ROUSH CleanTech Gen 4 Blue Bird Vision Propane
Service and Diagnosc Manual, 6.8L Ford Engine
56.8L Gen 4 Blue Bird Vision Propane Service and Diagnosc Manual
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Fill Staons
Propane is readily available anywhere in the United States. To
.
Note:
General Propane Refueling
therefore it is not required that the liquid level gauge or bleeder
required that the nozzle output pressure be at least 25 psi higher
•
•
If the door is not closed and locked to acvate the
switch (when equipped), the Mulplex will not send
the signal to the PCM to being the start sequence.
•
•
•
•
•
•
Propane Tank Refueling Procedure
tank.
Installaon, Garaging, and Training
Chapters 11 and 12 of NFPA 58 applies to engine fuel systems
Purging and Venng (Tanks and Lines)
General Propane Tank Informaon
ROUSH CleanTech Gen 4 Blue Bird Vision Propane
Service and Diagnosc Manual, 6.8L Ford Engine
66.8L Gen 4 Blue Bird Vision Propane Service and Diagnosc Manual
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NOTE: Some fuel staon pumps may have sucient pressure to
allow a small fuel ow into the tank even with the valves closed.
The operator should stop the ll as soon the fuel ow drops
noceably.
Vehicle Filling Procedure
always wear propane-safe gloves while
fueling a propane tank.
NOTE: Vehicle must be level, both front-to-rear and side-to-side,
when fueling. Failure to fuel on a level plane may lead to over or
under lls of the vehicle.
6. Verify the dispenser meter is set to zero.
a. The propane fueling nozzle must be fully engaged.
and the seal.
a gasoline type nozzle. The nozzles are also minimum
11. Turn on the propane dispenser/pump and begin the filling
a. Pay attention and never walk away from the filling
reading or the fuel level gauge on the dashboard.
from the valve to disengage.
Note: Some nozzles will have more pressure trapped between the
nozzle and the receptacle, so it is necessary to slowly unscrew the
connecon to allow pressure to bleed o before removing the
nozzle completely.
ROUSH CleanTech Gen 4 Blue Bird Vision Propane
Service and Diagnosc Manual, 6.8L Ford Engine
76.8L Gen 4 Blue Bird Vision Propane Service and Diagnosc Manual
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ROUSH CleanTech Fuel System Start Sequence
3. Open Tank Solenoid
4. Open FRPCM Supply Solenoid
5. Flush the Fuel Rails
6. Fuel Rail Pressure Builds
7. Engine Cranks
Requirements to Start
1.
and operate the bus.
2.
3.
4. The bus must be in Neutral. The bus will not start in any
other gear.
OPD Inspecon Procedure
NOTE: Test must be performed by a technician that has been trained
to ll or service propane cylinders and can only be performed on
vehicles with less than 50% fuel level, as indicated on the cluster.
it is level.
NOTE: Wear non-porous, cold- safe gloves, eye protecon, and ear
protecon during venng and repair operaons. Keep moisture
away from the valves. Failure to heed this warning can result in
personal injury.
NOTE: OPD might stop before white mist is visible at the bleeder
valve. This is normal as long as fuel gauge at the instrument
cluster reads Full. The tank may have stopped lling before
consistent liquid was visible at the bleeder valve. This indicates
normal operaon.
Example: A funconing OPD on a tank with a 100 gallon WC will
stop before ve (5) gallons (100 WC x .05 = 5) have been added
aer the mist is visible.
ROUSH CleanTech Gen 4 Blue Bird Vision Propane
Service and Diagnosc Manual, 6.8L Ford Engine
86.8L Gen 4 Blue Bird Vision Propane Service and Diagnosc Manual
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Blue Bird Vision Propane Fuel Rails
Le Hand Rail Assembly
Fuel Rail Return Line
Fuel Rail Supply Line
Bracket Supply
Line
Right Hand Rail Assembly
Integrated Pressure Temperature Sensor (IPTS)
ROUSH CleanTech Gen 4 Blue Bird Vision Propane
Service and Diagnosc Manual, 6.8L Ford Engine
96.8L Gen 4 Blue Bird Vision Propane Service and Diagnosc Manual
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Blue Bird Vision Propane Fuel Tanks
fuel system.
Supply
Filter
Tank Cover Plate
(covering Supply Valve, Return
Valve, and Bleeder Valve
Tank Access
Flange
Pressure
Relief Valve
(PRV)
Fr
ont of
T
ank/Bus
Rear of
Tank/Bus
Supply
Filter
Tank Cover Plate
(covering Supply Valve, Return
Valve, and Bleeder Valve
Tank Access
Flange
Pressure
Relief Valve
(PRV)
Fr
ont of
T
ank/Bus
Rear of
Tank/Bus
ROUSH CleanTech Gen 4 Blue Bird Vision Propane
Service and Diagnosc Manual, 6.8L Ford Engine
10 6.8L Gen 4 Blue Bird Vision Propane Service and Diagnosc Manual
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Bleeder
Hose
Remote
Bleeder
Valve
Remote
Fill
Valve
Electronic Fuel Pump Relays (EFPR)
Fill
Filter
Fuel Level
Sender (FLS)
Tank Pressure
Temperature Sensor
(TPTS)
Fill Valve/Overflow
Prevenon Device (OPD)
AA8A-9D412-C (Ford)
or 11995001
Low NOx
Cataly�c
Converter
ROUSH Badge
ROUSH CleanTech Oponal Ultra Low NOx Catalyst
Blue Bird Vision Propane Fuel Tanks (cont.)
ROUSH CleanTech Gen 4 Blue Bird Vision Propane
Service and Diagnosc Manual, 6.8L Ford Engine
116.8L Gen 4 Blue Bird Vision Propane Service and Diagnosc Manual
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ROUSH CleanTech Evaporave Emissions System
system.
Bleeding Down of the Rails:
Purging Fuel from the Canister:
System Self Tesng:
Component During Self Test When At Rest When Power is Applied
Vapor Management Valve (VMV) Closed Open
Vent Solenoid Open Closed
1. Vapor Canister
2. Vent Solenoid/Fresh Air Tube
3. FTPT Sensor
4. Bleed Port on the FRPCM
5. Vapor Management Valve (VMV)
6. RH Fuel Rail
7. Vapor Purge Hose Assembly
Vapor Canister
5
4
6
2
3
1
7
ROUSH CleanTech Gen 4 Blue Bird Vision Propane
Service and Diagnosc Manual, 6.8L Ford Engine
12 6.8L Gen 4 Blue Bird Vision Propane Service and Diagnosc Manual
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PREPARATION FOR FUEL SYSTEM SERVICE
Manual Shuto Valve
Descripon
Closing the Manual Shuto Valve
with a tool.
Opening the Manual Fuel Shuto
NOTE: Aer all fuel service procedures are completed, follow
the Fuel System Priming Procedure.
Tank Cover Plate
(covering Supply Valve, Return Valve,
and Bleeder Valve
Manual Shuto Valve
Manual Fuel Shutoff Valve
SPECIAL TOOLS
Electronic Leak Detector or Leak Detecng Soluon
ROUSH CleanTech Transfer Kit
Propane Flare
autogas.
Do not aempt to build your own propane are. Failure to exercise
extreme cauon and care may lead to serious accidents which
can result in property damage, personal injury, and/or death.
Check with your local re marshal or your local LPA supplier
prior to using a propane are.
Laptop, J2534 Pass Through Device and the ROUSH
Diagnosc Tool (RDT)
found in the of the manual.
Block Heaters
heaters are only used in areas where the temperature drops to
ROUSH CleanTech Gen 4 Blue Bird Vision Propane
Service and Diagnosc Manual, 6.8L Ford Engine
136.8L Gen 4 Blue Bird Vision Propane Service and Diagnosc Manual
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Fuel Line Purging/Depressurizaon
Clearing the propane out of the fuel lines (purging) is required
amount of vapor released harmlessly into the atmosphere and
NOTE: Operang the fuel pumps without fuel may lead to
premature failure of fuel pumps.
supply and return fuel lines of most of the liquid propane.
NOTE: This step may set fault codes to due to pump being
unplugged and inability to build fuel rail pressure. These codes
should be cleared before returning vehicle to service.
terminal.
NOTE: Watch for liquid propane dripping from the line connecon.
7. Slowly open the line at the return valve on the tank to allow
O-ring if damaged.
NOTE: Use an O-ring installaon tool to limit potenal damage
to O-ring during installaon.
NOTE: There may sll be a small amount of propane vapor in
the lines aer running this procedure. Open the lines slowly and
cauously to bleed o any remaining propane.
ROUSH CleanTech Gen 4 Blue Bird Vision Propane
Service and Diagnosc Manual, 6.8L Ford Engine
14 6.8L Gen 4 Blue Bird Vision Propane Service and Diagnosc Manual
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on the transferring tank may have tripped. If the EFV
When the tank is near empty there will be a tonal
to the pumps.
fuel pressure.
NOTE: Fuel will be under pressure in the transfer line; use cauon
when disconnecng the ngs, slowly loosen the ngs, and
use gloves and protecve eye wear.
perform the Verifying Tank DP.
Draining the Tank Using a Propane Flare or Tower
Before starng this process, check with your local re marshal
or your local propane supplier about regulaons prevenng the
use of a propane are prior to using a propane are.
Draining the Tank by Venng the Vapor to the Atmosphere
Before starng this process, check with your local re marshal
or your local propane supplier about regulaons prevenng
propane venng prior to venng the tank.
NOTE: Wear non-porous, cold- safe gloves, eye protecon, and
ear protecon during venng.
NOTE: If you have any quesons or concerns or you feel unqualied
to perform the process of venng the tank, contact your local
propane provider or ROUSH CleanTech (800) 59-ROUSH (597-6874).
Fuel Tank Draining Procedure
NOTE: Keep at least 35 away from heat, sparks, ames, stac
electricity, lighted smoking materials, or other sources of ignion
when draining a tank. Failure to heed this danger may result in
severe personal injury or death.
Overview
The fuel tank must be empty of propane before most tank
•
•
•
Preparing for Fuel Tank Transfer or Flare
tank to be drained.
3. Purge the fuel lines by using the Fuel Line Purging/
.
Using In-Tank Pumps to Transfer the Fuel
NOTE: This method will not completely drain the tank and a
venng the tank to atmosphere will sll be required. In some
areas this is not allowed or may not be safe. In this case, the fuel
must be burned o.
•
•
•
5. Slowly open the manual supply valve on the tank to be drained.
You should hear the pumps in the fuel tank running and fuel
will begin to transfer the fuel.
Failure to turn the
pumps o immediately can lead to pump damage.
• Measuring amperage.
ROUSH CleanTech Gen 4 Blue Bird Vision Propane
Service and Diagnosc Manual, 6.8L Ford Engine
156.8L Gen 4 Blue Bird Vision Propane Service and Diagnosc Manual
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Fuel Tank Purging Procedure
Always follow all NFPA 58 guidelines (paragraphs 7.3.1 and 7.3.2)
when working on the propane fuel system or refueling a vehicle,
you must be in a well-venlated area at least 35 from any
ignion source and 35 from any acvity that throws sparks or
risk severe personal injury or death.
Descripon
pressure.
vapor purging.
Vacuum Purging Procedure
perform the and Verifying Tank
valve.
NOTE: Only use an explosion-proof (pneumac powered) vacuum
pump to prevent ignion of a potenally combusble air/fuel
mixture. Explosion-proof pumps are specially designed to enclose
parts of the pump that could ignite vapors that may result in an
explosion.
least 15 minutes. Close the bleeder valve and remove the
6. Slowly pressurize the tank with propane.
NOTE: This can be done with a vapor propane source or connecng
to a ll staon without turning on the ll staon pump. This will
pressurize the tank using the remaining fuel in the staon ll line.
to pressurize the fuel lines
.
Vapor Purging Procedure
perform the and Verifying Tank
Verifying Tank Depressurizaon
Note: There may sll be a small amount of propane in the tank
prior to running this procedure.
NOTE: Before removing any components from the fuel tank, it
is very important to verify there is not any pressure remaining
inside. The technician that is removing a tank component should
always be the one to verify it is empty. This should be done right
before starng the repair. Failure to do so could result in severe
personal injury or death and/or damage to property.
1.
The tank should be depressurized using your preferred NFPA 58
approved method. Refer to the .
2.
Purge the fuel lines using the Fuel Line Purg
.
3.
4.
needle is on E.
5.
6.
7.
key it to OFF.
8.
9.
removed from the tank.
10.
Note: For components threaded into the tank, slowly loosen
them. For components fastened to the tank with a ange, slowly
loosen each bolt unl the component can move freely, then the
component can be removed from the tank.
NOTE: Aer depressurizing, there will sll be propane vapors
in the tank. Keep tank away from any sources of ignion and
only use hand tools inside the tank. A depressurized tank can
re-pressurize itself if re-sealed.
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