Gen 1 CNG Frame Mount FSM Parts Manual

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

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. 25242 Arctic Ocean Drive Lake Forest, CA 92630 USA Tel: 949.930.3400 Fax: 949.930.3401 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. 2015 Quantum Fuel Systems Technologies Worldwide, Inc. i

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

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 800.816.8691. 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 114278 25X60 RH FSM PN 114482 25X80 RH FSM PN 114233 25X90 RH FSM PN 116241 25X60 RH FSM, SLAVE PN 116102 25X80 RH FSM, SLAVE PN 114985 25X90 RH FSM, SLAVE PN 116646 25X90 RH FSM, W/ REGULATOR PN 115240 25X80 LH FSM PN 114790 25X90 LH FSM PN 116263 25X60 LH FSM, SLAVE PN 115306 25X80 LH FSM, SLAVE PN 115533 25X90 LH FSM, SLAVE PN 116647 25X90 LH FSM, W/ REGULATOR PN 117034 25X90 LH FSM, HIGH FLOW iii

Module Identification Generation 1 114278, 114482, 114233, 115240, 114790 Fill Panel 116241, 116102, 114985, 116263, 115306, 115533 No Fill Panel (Slave) 116646, 116647 W/ Regulator 117034 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

Table of Contents Fuel Storage Module Covers... 1 Fuel Storage Module Fuel Lines... 5 Fuel Storage Module Brackets... 9 Fuel Storage Module Labels... 11 Accessories... 13 Limited Warranty For Composite Cylinders... 14 v

Fuel Storage Module Covers 1

Fuel Storage Module Covers Item Qty Quantum Part No. Description 101 6 110926 004 BOLT HEX HD FLG 3/8 ( 16), 1.25 102 6 114334 001 NUT FLANGE, NYLON LOCKING, 5/16 ( 18) 103 3 114275 BRACKET LOWER STEP 104 6 115263 HOLD DOWN ASSEMBLY STEPS 105 1 114897 114243 115251 114484 114287 115538 114991 115315 116099 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 106 2 114213-004 EXTRUDED STEP 5 WIDE 108 1 116215 115990 END CAP ASSEMBLY FRONT LH END CAP ASSEMBLY FRONT RH 109 20 116421 008 LOCK NUT FLANGED, 5/8 ( 11) 110 20 114325 001 WASHER SAE, 5/8 ( 11) 111 12 115553 175 BOLT HEX CAP, 5/8 ( 11), 1.75 112 1 114899 114066 115242 114487 114282 115545 114989 115311 116096 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 113 3 114810 BRACKET UPPER STEP 117 1 114283 LATCH DOOR ACCESS 2

118 1 114798 DOOR ACCESS TOP Fuel Storage Module Covers Item Qty Quantum Part No. Description 119 34-49 116668 BOLT HEX HEAD CONICAL WASHER 5/16 ( 18) 122 4 4 115553 225 115553 425 BOLT HEX CAP 5/8 ( 11) 2.25 BOLT HEX CAP 5/8 ( 11) 4.25 123 24 10 115378-005 115378-008 U-NUT 5/16 ( 18) SHORT U-NUT 5/16 ( 18) LONG 124 1 116494 BRACKET ASM UPPER COVER 125 1 126 1 116216 115984 116222 116130 114824 114812 115245 114759 114286 115536 114993 115313 116142 END CAP REAR 90 80 LH FILL END CAP REAR 90 80 60 RH FILL END CAP ASSEMBLY REAR 90 80 60 LH SLAVE END CAP ASSEMBLY REAR 90 80 60 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 127 2 116493 BRACKET SUPPORT BACK COVER 128 6 N1-20300-004 LOCK NUT FLANGED, M10 129 2 116081 SUPPORT END CAP 130 1 114086-024 FOAM ADHESIVE STRIP, 1/16 X 24, CUT TO LENGTH 131 1 115490 FOAM ADHESIVE STRIP, 1/16 X 12, CUT TO LENGTH 132 6 S1-20298-012 BOLT HEX CAP, M10 X 30 3

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Fuel Storage Module Fuel Lines 5

Fuel Storage Module Fuel Lines Item Qty Quantum Part No. Description 300 8 S3 20503 011 O RING 9/16 ( 6) SAE, ST THD 301 1 S3 20503 055 O RING FILL RECEPTACLE, HIGH FLOW 302 1 S3 20503 003 O RING FILL RECEPTACLE, STANDARD 303 1 111409-216 O RING VALVE TO CYLINDER 304 10 S3 20503 008 O RING 3/8 ( 6) ORFS 305 1 103501 002 FITTING COUPLING, 9/16 ( 18) SAE 306 2 114293 002 PLUG HEX, 9/16 18 307 1 113522 VALVE BLEED, CNG HIGH PRESSURE 308 1 106904 005 FITTING ADAPTER, VNT VLV 309 2 103959 001 FITTING CROSS, 3/8 310 3 108896 006 LOCKNUT NYLON, M4 311 1 113715 GAUGE FUEL PRESSURE 312 3 114079 005 SCREW PHILLIPS, M4 X 12 313 1 114998 115035 FUEL LINE TEE TO VALVE, LH FUEL LINE TEE TO VALVE, RH 314 2 103957 001 FITTING TEE, 3/8 315 1 114499 FUEL LINE TEE TO 1/4 TURN VALVE 316 2 116594 VALVE 1/4 TURN ISOLATION, ORFS 317 1 114516 FUEL LINE 1/4 TURN VALVE TO GAUGE 318 1 114345 FILL RECEPTICLE HIGH FLOW 319 1 114928 FILL RECEPTICLE STANDARD FILL 320 1 114498 FUEL LINE FILL TO FITTING 321 3 103976 001 FITTING PORT CONNECTOR, 1/2 322 2 S1-20381-017 BOLT HEX HEAD, M8 X 20 323 1 114494 FUEL LINE 1/4 TURN TO FITTING, RH 324 2 F4-20469-002 FITTING UNION, -6 SAE TO -6 ORFS 325 1 115283 CHECK VALVE 3/8 6

Fuel Storage Module Fuel Lines Item Qty Quantum Part No. Description 329 1 114997 115036 FUEL LINE TEE TO TEE, LH FUEL LINE TEE TO TEE, RH 330 3 110926 005 BOLT 3/8 ( 16) 331 3 115933 009 RUBBER MOUNT 332 3 115020 002 115020 003 CLAMP TUBE 3/8 CLAMP TUBE 1/2 333 3 116421 005 LOCK NUT FLANGED, 3/8 ( 16) 334 1 102366 005 FITTING ELBOW 335 1 C2 20750 INSULATOR TUBE 3/8 336 2 114405 PRD REMOTE, VTI 337 2 338 1 115785 006 105560 012 116158 116171 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, 3/8 340 1 115321 002 FITTING TEE 3/8 ( 6) 341 1 114505 116323 102270 103118 FILTER ASSEMBLY COALESCING, OMNITEK FILTER REPLACEMENT KIT, OMNITEK FILTER ASSEMBLY COALESCING, PARKER FILTER REPLACEMENT KIT, PARKER 342 1 105975 002 FITTING ELBOW 343 1 344 1 347 1 114946 114919 116205 116160 116207 116170 116366 114413 116287 116286 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 348 1 116621 DUST CAP FILL RECEPTACLE, HIGH FLOW 349 1 114816 VALVE MANUAL, 1 1/8 7

Fuel Storage Module Fuel Lines Item Qty Quantum Part No. Description 350 1 116620 DUST CAP FILL RECEPTACLE, STANDARD 351 1 116154 116169 116203 116206. 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

Fuel Storage Module Brackets 9

Fuel Storage Module Brackets Item Qty Quantum Part No. Description 400 *IF REPLACING, ADD ITEM 418 1 113899 114093 114093-100 113974 CNG CYLINDER 90, 603L CNG CYLINDER 80, 534L (CANADA) CNG CYLINDER 80, 534L (USA) CNG CYLINDER 60, 392L 401 2 111964 003 PIN COTTER, CLEVIS PIN, 1/8 X 1 402 2 115569 002 EYE BOLT TENSION 403 4 114325 001 WASHER SAE, 5/8 ( 11) 404 2 113968 CLEVIS PIN 405 2 116488 CYLINDER SUPPORT BRACKET 406 2 116416 009 CYLINDER BRACKET ISOLATOR 407 *IF REPLACING, ADD ITEMS 415, 416, 417 408 *IF REPLACING, ADD ITEMS 415, 416, 417 2 114895 101 CYLINDER STRAP ISOLATOR 2 114323 001 LOWER CYLINDER STRAP RETAINING NUT 1/2 ( 13) 409 2 113973 LOWER CYLINDER STRAP BOLT 410 2 116989 CYLINDER STRAP 411 2 113970 SPRING SADDLE 412 2 115704 COMPRESSION SPRING 413 2 116421 008 LOCK NUT FLANGE, 5/8 ( 11) 414 2 117161-002 STRAP ASSEMBLY (WITH ISOLATOR) 415 1 117330-001 ADHESIVE ASI, CYLINDER ISOLATOR 416 1 117504 MIXER NOZZLE ASI ADHESIVE 417 1 117505 DISPENSING GUN ASI 418 1 117222 POSITIONING KIT CYLINDER BLOCK 10

Fuel Storage Module Labels 11

Fuel Storage Module Labels Item Qty Quantum Part No. Description 450 1 116535 LABEL FILL CHECK BY PASS VALVE 451 2 113224 LABEL CYLINDER SAFETY INFO 452 2 113446 LABEL CYLINDER STATIC INFO 453 2 113532 LABEL CNG CYLINDER MANU INFO (CONTACT QUANTUM) 454 2 114006 LABEL CYLINDER BRACKET (TRRC) 455 2 114254 LABEL CNG DIAMOND 456 1 116140 LABEL CYLINDER EXPIRATION 457 1 116540 LABEL CYLINDER SHUTOFF VALVE 458 1 114264 114930 LABEL FILL PANEL, RH LABEL FILL PANEL, LH 459 1 114270 LABEL VENT VALVE 460 1 116552 LABEL SERIAL NUMBER 12

Accessories PN 114949 1 (25mm) Spacer Kit PN 114954 2 (51mm) Spacer Kit PN 116544 Insulation Kit Quantum Part No. Description 114949 SPACER KIT 1 (25mm) 114954 SPACER KIT 2 (51mm) 116544 INSULATION KIT 13

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

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. 2015 Quantum Fuel Systems Technologies Worldwide, Inc.

Quantum Technologies Worldwide, Inc. 25242 Arctic Ocean Drive Lake Forest, CA 92630 Tel: (949) 930 3400 Fax: (949) 930 3401 www.qtww.com info@qtww.com