Gen 1 CNG Frame Mount FSM Parts Manual

Transcription

1 Gen 1 CNG Frame Mount FSM Parts Manual Printed September 2, 2015 Rev D

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3 Preface FSM Parts Manual To reduce the chance of personal injury and/or property damage, the following instructions must be carefully observed: Proper installation, service, and repair are important to the safety of the service technician and the safe, reliable operation of all motor vehicles. If part replacement is necessary, the part must be replaced with one of the same part number or with an equivalent part. Do not use replacement parts of lesser quality. Accordingly, anyone who intends to use a replacement part which is not in this manual, must first determine neither his safety nor the safe operation of the vehicle will be jeopardized by the replacement part selected. If you need further information or have any questions, please contact: Quantum Fuel Systems Technologies Worldwide, Inc Arctic Ocean Drive Lake Forest, CA USA Tel: Fax: All information, illustrations, and specifications are based on the latest product information available at the time of printing. Quantum Fuel Systems Technologies Worldwide, Inc. reserves the right to make changes at any time without notice. This information is the intellectual property of Quantum Fuel Systems Technologies Worldwide, Inc. and may not be altered in any way. This information is protected by the copyright laws of the United States of America, and other countries, and may not be reproduced, stored in any retrieval system, or transmitted in any form or by any means (including but not limited to electronic, mechanical, photocopying, and recording) without the prior written permission of Quantum Fuel Systems Technologies Worldwide, Inc Quantum Fuel Systems Technologies Worldwide, Inc. i

4 How to Use This Manual This parts manual contains information specific to the CNG Frame Mount fuel storage module (FSM). It does not explain everything you need to know about servicing your equipment. This manual contains information for the CNG Gen 1 Frame Mount fuel storage module. ii

5 Ordering Parts To purchase repair or replacement parts for the CNG Gen 1 Frame Mount Fuel Storage Module, contact your local Quantum sales representative. Technical Assistance For questions regarding the installation, maintenance, and service for the CNG Gen 1 Frame Mount Fuel Storage Module, contact Quantum Technical Assistance at Price List Published prices are accurate at the time of print and are subject to change without notice. For part pricing, contact your local Quantum sales representative. This manual is for use only for the following FSM Part Numbers: PN X60 RH FSM PN X80 RH FSM PN X90 RH FSM PN X60 RH FSM, SLAVE PN X80 RH FSM, SLAVE PN X90 RH FSM, SLAVE PN X90 RH FSM, W/ REGULATOR PN X80 LH FSM PN X90 LH FSM PN X60 LH FSM, SLAVE PN X80 LH FSM, SLAVE PN X90 LH FSM, SLAVE PN X90 LH FSM, W/ REGULATOR PN X90 LH FSM, HIGH FLOW iii

6 Module Identification Generation , , , , Fill Panel , , , , , No Fill Panel (Slave) , W/ Regulator High Flow All of the Generation 1 Frame Mount FSMs will have a lower cover that is not equipped with bolts that attach the lower cover to the cylinder mounting brackets. There will only be cover bolts along the perimeter of the lower cover. The Generation 1 Frame Mount FSMs which are equipped with a regulator and fuel control module are identified with 6 bolts on the rear end cap. The 2 lower bolts on the end cap are used to mount the regulator. The 4 upper bolts on the end cap are used to mount the bracket for the fuel control module. The Generation 1 Frame Mount FSMs that are built for high flow capacity can be identified with the check valve and mount attached to the inside of the rear end cap. iv

7 Table of Contents Fuel Storage Module Covers... 1 Fuel Storage Module Fuel Lines... 5 Fuel Storage Module Brackets... 9 Fuel Storage Module Labels Accessories Limited Warranty For Composite Cylinders v

8 Fuel Storage Module Covers 1

9 Fuel Storage Module Covers Item Qty Quantum Part No. Description BOLT HEX HD FLG 3/8 ( 16), NUT FLANGE, NYLON LOCKING, 5/16 ( 18) BRACKET LOWER STEP HOLD DOWN ASSEMBLY STEPS COVER LOWER 90 LH FILL COVER LOWER 90 RH FILL COVER LOWER 80 LH FILL COVER LOWER 80 RH FILL COVER LOWER 60 RH FILL COVER LOWER 90 LH SLAVE COVER LOWER 90 RH SLAVE COVER LOWER 80 LH SLAVE COVER LOWER 80 RH SLAVE * ALL ASSEMBLIES INCLUDE STEP EXTRUDED STEP 5 WIDE END CAP ASSEMBLY FRONT LH END CAP ASSEMBLY FRONT RH LOCK NUT FLANGED, 5/8 ( 11) WASHER SAE, 5/8 ( 11) BOLT HEX CAP, 5/8 ( 11), COVER UPPER 90 LH FILL COVER UPPER 90 RH FILL COVER UPPER 80 LH FILL COVER UPPER 80 RH FILL COVER UPPER 60 RH FILL COVER UPPER 90 LH SLAVE COVER UPPER 90 RH SLAVE COVER UPPER 80 LH SLAVE COVER UPPER 80 RH SLAVE * ALL ASSEMBLIES INCLUDE STEP AND ACCESS DOOR BRACKET UPPER STEP LATCH DOOR ACCESS 2

10 DOOR ACCESS TOP Fuel Storage Module Covers Item Qty Quantum Part No. Description BOLT HEX HEAD CONICAL WASHER 5/16 ( 18) BOLT HEX CAP 5/8 ( 11) 2.25 BOLT HEX CAP 5/8 ( 11) U-NUT 5/16 ( 18) SHORT U-NUT 5/16 ( 18) LONG BRACKET ASM UPPER COVER END CAP REAR LH FILL END CAP REAR RH FILL END CAP ASSEMBLY REAR LH SLAVE END CAP ASSEMBLY REAR RH SLAVE COVER BACK 90 LH FILL COVER BACK 90 RH FILL COVER BACK 80 LH FILL COVER BACK 80 RH FILL COVER BACK 60 RH FILL COVER BACK 90 LH SLAVE COVER BACK 90 RH SLAVE COVER BACK 80 LH SLAVE COVER BACK 80 RH SLAVE BRACKET SUPPORT BACK COVER N LOCK NUT FLANGED, M SUPPORT END CAP FOAM ADHESIVE STRIP, 1/16 X 24, CUT TO LENGTH FOAM ADHESIVE STRIP, 1/16 X 12, CUT TO LENGTH S BOLT HEX CAP, M10 X 30 3

11 This Page Intentionally Left Blank 4

12 Fuel Storage Module Fuel Lines 5

13 Fuel Storage Module Fuel Lines Item Qty Quantum Part No. Description S O RING 9/16 ( 6) SAE, ST THD S O RING FILL RECEPTACLE, HIGH FLOW S O RING FILL RECEPTACLE, STANDARD O RING VALVE TO CYLINDER S O RING 3/8 ( 6) ORFS FITTING COUPLING, 9/16 ( 18) SAE PLUG HEX, 9/ VALVE BLEED, CNG HIGH PRESSURE FITTING ADAPTER, VNT VLV FITTING CROSS, 3/ LOCKNUT NYLON, M GAUGE FUEL PRESSURE SCREW PHILLIPS, M4 X FUEL LINE TEE TO VALVE, LH FUEL LINE TEE TO VALVE, RH FITTING TEE, 3/ FUEL LINE TEE TO 1/4 TURN VALVE VALVE 1/4 TURN ISOLATION, ORFS FUEL LINE 1/4 TURN VALVE TO GAUGE FILL RECEPTICLE HIGH FLOW FILL RECEPTICLE STANDARD FILL FUEL LINE FILL TO FITTING FITTING PORT CONNECTOR, 1/ S BOLT HEX HEAD, M8 X FUEL LINE 1/4 TURN TO FITTING, RH F FITTING UNION, -6 SAE TO -6 ORFS CHECK VALVE 3/8 6

14 Fuel Storage Module Fuel Lines Item Qty Quantum Part No. Description FUEL LINE TEE TO TEE, LH FUEL LINE TEE TO TEE, RH BOLT 3/8 ( 16) RUBBER MOUNT CLAMP TUBE 3/8 CLAMP TUBE 1/ LOCK NUT FLANGED, 3/8 ( 16) FITTING ELBOW C INSULATOR TUBE 3/ PRD REMOTE, VTI PRD (VTI) DUST CAP PRD (CIRCLE SEAL) DUST CAP PRD DISCHARGE PIPE PRD TO PRD 90, 3/8 PRD DISCHARGE PIPE PRD TO PRD 80, 3/ FITTING TEE 3/8 ( 6) FILTER ASSEMBLY COALESCING, OMNITEK FILTER REPLACEMENT KIT, OMNITEK FILTER ASSEMBLY COALESCING, PARKER FILTER REPLACEMENT KIT, PARKER FITTING ELBOW FUEL LINE 1/4 TURN TO TEE, LH FUEL LINE 1/4 TURN TO TEE, RH PRD DISCHARGE PIPE VALVE TO PRD, LH 90 PRD DISCHARGE PIPE VALVE TO PRD, RH 90 PRD DISCHARGE PIPE VALVE TO PRD, LH 80 PRD DISCHARGE PIPE VALVE TO PRD, RH 80 PRD DISCHARGE PIPE VALVE TO PRD, LH 60 PRD DISCHARGE PIPE VALVE TO PRD, RH 60 FUEL LINE CROSS TO FILTER LH FUEL LINE CROSS TO FILTER RH DUST CAP FILL RECEPTACLE, HIGH FLOW VALVE MANUAL, 1 1/8 7

15 Fuel Storage Module Fuel Lines Item Qty Quantum Part No. Description DUST CAP FILL RECEPTACLE, STANDARD PRD MANIFOLD ASM VTI, RH 90 PRD MANIFOLD ASM VTI, RH 80 PRD MANIFOLD ASM VTI, LH 90 PRD MANIFOLD ASM VTI, LH 80 * Includes: 305, 330, 331, 332, 333, 334, 335, 336, 337, 338, 340, 344 8

16 Fuel Storage Module Brackets 9

17 Fuel Storage Module Brackets Item Qty Quantum Part No. Description 400 *IF REPLACING, ADD ITEM CNG CYLINDER 90, 603L CNG CYLINDER 80, 534L (CANADA) CNG CYLINDER 80, 534L (USA) CNG CYLINDER 60, 392L PIN COTTER, CLEVIS PIN, 1/8 X EYE BOLT TENSION WASHER SAE, 5/8 ( 11) CLEVIS PIN CYLINDER SUPPORT BRACKET CYLINDER BRACKET ISOLATOR 407 *IF REPLACING, ADD ITEMS 415, 416, *IF REPLACING, ADD ITEMS 415, 416, CYLINDER STRAP ISOLATOR LOWER CYLINDER STRAP RETAINING NUT 1/2 ( 13) LOWER CYLINDER STRAP BOLT CYLINDER STRAP SPRING SADDLE COMPRESSION SPRING LOCK NUT FLANGE, 5/8 ( 11) STRAP ASSEMBLY (WITH ISOLATOR) ADHESIVE ASI, CYLINDER ISOLATOR MIXER NOZZLE ASI ADHESIVE DISPENSING GUN ASI POSITIONING KIT CYLINDER BLOCK 10

18 Fuel Storage Module Labels 11

19 Fuel Storage Module Labels Item Qty Quantum Part No. Description LABEL FILL CHECK BY PASS VALVE LABEL CYLINDER SAFETY INFO LABEL CYLINDER STATIC INFO LABEL CNG CYLINDER MANU INFO (CONTACT QUANTUM) LABEL CYLINDER BRACKET (TRRC) LABEL CNG DIAMOND LABEL CYLINDER EXPIRATION LABEL CYLINDER SHUTOFF VALVE LABEL FILL PANEL, RH LABEL FILL PANEL, LH LABEL VENT VALVE LABEL SERIAL NUMBER 12

20 Accessories PN (25mm) Spacer Kit PN (51mm) Spacer Kit PN Insulation Kit Quantum Part No. Description SPACER KIT 1 (25mm) SPACER KIT 2 (51mm) INSULATION KIT 13

21 Limited Warranty For Composite Cylinders Warranty and Product Return Information are located at Cylinder Label Request Form Limited Warranty Composite Cylinders Limited Warranty Parts & Components Product Return Instructions RMAR Form 14

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23 Revision History Revision X1 (12/12/14) Draft release. Revision A (01/15/15) Updated part descriptions, added part numbers, added quantity, updated fuel line illustration, and format title changes. Revision B (01/22/15) Updated part number. Revision C (09/01/15) Updated Forward and Preface. Added Module Identification. Updated part numbers and quantities. Revision D (09/02/15) Updated Fuel Storage Module Fuel Lines drawing. Updated page numbering. All information, illustrations, and specifications are based on the latest product information available at the time of printing. Quantum Fuel Systems Technologies Worldwide, Inc. reserves the right to make changes at any time without notice. This information is the intellectual property of Quantum Fuel Systems Technologies Worldwide, Inc. and may not be altered in any way. This information is protected by the copyright laws of the United States of America, and other countries, and may not be reproduced, stored in any retrieval system, or transmitted in any form or by any means (including but not limited to electronic, mechanical, photocopying, and recording) without the prior written permission of Quantum Fuel Systems Technologies Worldwide, Inc Quantum Fuel Systems Technologies Worldwide, Inc.

24 Quantum Technologies Worldwide, Inc Arctic Ocean Drive Lake Forest, CA Tel: (949) Fax: (949)