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Gen 1 CNG Frame Mount FSM Parts Manual
Gen 1 CNG Frame Mount FSM Parts Manual Printed January 26, 2016 Rev E FSM Parts Manual Preface 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. 2016 Quantum Fuel Systems Technologies Worldwide, Inc. ii FSM Parts Manual 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. iii FSM Parts Manual Ordering Parts To purchase repair or replacement parts, use the online Parts Request Form. Retail parts pricing and the Parts Request Form are accessible at www.qtww.com or send a request to [email protected] Technical Assistance For questions regarding the installation, maintenance, and service for the CNG Fuel Storage Module, contact Quantum Technical Assistance at 800.816.8691. 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 Refer to Appendix A at the back of this manual for detailed size information and general specifications. iv FSM Parts Manual 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. v FSM Parts Manual Table of Contents Fuel Storage Module Covers........................................................................................................................................ 1 Fuel Storage Module Covers........................................................................................................................................ 2 Fuel Storage Module Fuel Lines .................................................................................................................................. 5 Fuel Storage Module Brackets..................................................................................................................................... 9 Fuel Storage Module Labels ...................................................................................................................................... 11 Accessories ................................................................................................................................................................. 13 Appendix A - General System Specifications .......................................................................................................... 14 vi FSM Parts Manual Fuel Storage Module Covers 1 FSM Parts Manual Fuel Storage Module Covers Item Qty Quantum Description Part No. 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 114897 COVER – LOWER 90” LH FILL 114243 COVER – LOWER 90” RH FILL 115251 COVER – LOWER 80” LH FILL 114484 COVER – LOWER 80” RH FILL 114287 COVER – LOWER 60” RH FILL 115538 COVER – LOWER 90” LH SLAVE 114991 COVER – LOWER 90” RH SLAVE 115315 COVER – LOWER 80” LH SLAVE 116099 COVER – LOWER 80” RH SLAVE 114213–004 EXTRUDED STEP – 5” WIDE 116215 END CAP ASSEMBLY – FRONT LH 115990 END CAP ASSEMBLY – FRONT RH 105 1 106 2 108 1 109 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” 114899 COVER – UPPER 90” LH FILL 114066 COVER – UPPER 90” RH FILL 115242 COVER – UPPER 80” LH FILL 114487 COVER – UPPER 80” RH FILL 114282 COVER – UPPER 60” RH FILL 115545 COVER – UPPER 90” LH SLAVE 114989 COVER – UPPER 90” RH SLAVE 115311 COVER – UPPER 80” LH SLAVE 116096 COVER – UPPER 80” RH SLAVE 112 1 113 3 114810 BRACKET – UPPER STEP 117 1 114283 LATCH – DOOR ACCESS 2 FSM Parts Manual Fuel Storage Module Covers Item Qty Quantum Description Part No. 118 1 114798 DOOR – ACCESS TOP 119 34–49 116668 BOLT – HEX HEAD CONICAL WASHER 5/16 (–18) 4 115553–225 BOLT – HEX CAP 5/8 (–11) 2.25” 4 115553–425 BOLT – HEX CAP 5/8 (–11) 4.25” 24 115378–005 U–NUT – 5/16 (–18) SHORT 10 115378–008 U–NUT – 5/16 (–18) LONG 1 116494 BRACKET ASM – UPPER COVER 116216 END CAP – REAR 90” 80” LH FILL 115984 END CAP – REAR 90” 80” 60” RH FILL 116222 END CAP ASSEMBLY – REAR 90” 80” 60” LH SLAVE 116130 END CAP ASSEMBLY – REAR 90” 80” 60” RH SLAVE 114824 COVER – BACK 90” LH FILL 114812 COVER – BACK 90” RH FILL 115245 COVER – BACK 80” LH FILL 114759 COVER – BACK 80” RH FILL 114286 COVER – BACK 60” RH FILL 115536 COVER – BACK 90” LH SLAVE 114993 COVER – BACK 90” RH SLAVE 115313 COVER – BACK 80” LH SLAVE 116142 COVER – BACK 80” RH SLAVE 122 123 124 125 126 1 1 127 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 FSM Parts Manual This Page Intentionally Left Blank 4 FSM Parts Manual Fuel Storage Module Fuel Lines 5 FSM Parts Manual Fuel Storage Module Fuel Lines Item Qty Quantum Description Part No. 300 8 116702-906 O–RING – 9/16 (–6) SAE, ST THD 301 1 116702-208 O–RING – FILL RECEPTACLE, HIGH FLOW 302 1 116702-110 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 FUEL LINE – TEE TO VALVE, LH 115035 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 114444 FILL RECEPTACLE – HIGH FLOW, FILTERED, 1/2” 114345 FILL RECEPTACLE – HIGH FLOW, FILTERED, 3/8” 319 1 114928 FILL RECEPTACLE – STANDARD FILL, NO FILTER, 3/8” 115516 FILL RECEPTACLE – STANDARD FILL, FILTERED, 3/8” 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 FSM Parts Manual Fuel Storage Module Fuel Lines Item Qty Quantum Description Part No. 114997 FUEL LINE – TEE TO TEE, LH 115036 FUEL LINE – TEE TO TEE, RH 3 110926–005 BOLT – 3/8 (–16) 331 3 115933–009 RUBBER MOUNT 332 3 115020–002 LOOP CLAMP – TUBE 3/8” 115020–003 LOOP 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 115785–006 PRD (VTI) DUST CAP 105560–012 PRD (CIRCLE SEAL) DUST CAP 338 1 116158 PRD DISCHARGE PIPE – PRD TO PRD 90”, 3/8” 116171 PRD DISCHARGE PIPE – PRD TO PRD 80”, 3/8” 340 1 115321–002 FITTING – TEE 3/8 (–6) 114505 FILTER ASSEMBLY – COALESCING, OMNITEK 116323 FILTER – REPLACEMENT KIT, OMNITEK 102270 FILTER ASSEMBLY – COALESCING, PARKER 103118 FILTER – REPLACEMENT KIT, PARKER 105975–002 FITTING – ELBOW 114946 FUEL LINE – 1/4 TURN TO TEE, LH 114919 FUEL LINE – 1/4 TURN TO TEE, RH 116205 PRD DISCHARGE PIPE – VALVE TO PRD, LH 90” 116160 PRD DISCHARGE PIPE – VALVE TO PRD, RH 90” 116207 PRD DISCHARGE PIPE – VALVE TO PRD, LH 80” 116170 PRD DISCHARGE PIPE – VALVE TO PRD, RH 80” 116366 PRD DISCHARGE PIPE – VALVE TO PRD, LH 60” 114413 PRD DISCHARGE PIPE – VALVE TO PRD, RH 60” 116287 FUEL LINE – CROSS TO FILTER LH 116286 FUEL LINE – CROSS TO FILTER RH 329 1 330 341 1 342 1 343 1 344 1 347 1 348 1 116621 DUST CAP – FILL RECEPTACLE, HIGH FLOW 349 1 114816 VALVE – MANUAL, 1–1/8” 7 FSM Parts Manual Fuel Storage Module Fuel Lines Item Qty Quantum Description Part No. 350 351 1 1 116620 DUST CAP – FILL RECEPTACLE, STANDARD 116154 PRD MANIFOLD ASM – VTI, RH 90” 116169 PRD MANIFOLD ASM – VTI, RH 80” 116203 PRD MANIFOLD ASM – VTI, LH 90” 116206 . PRD MANIFOLD ASM – VTI, LH 80” * Includes: 305, 330, 331, 332, 333, 334, 335, 336, 337, 338, 340, 344 8 FSM Parts Manual Fuel Storage Module Brackets 9 FSM Parts Manual Fuel Storage Module Brackets Item Qty Quantum Description Part No. 400 *IF REPLACING, ADD ITEM 418 1 113899 CNG CYLINDER 90”, 603L 114093 CNG CYLINDER 80”, 534L (CANADA) 114093–100 CNG CYLINDER 80”, 534L (USA) 113974 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 117378–002 CYLINDER BRACKET ISOLATOR 2 114895–101 CYLINDER STRAP ISOLATOR *IF REPLACING, ADD ITEMS 415, 416, 417 2 116421–006 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 407 *IF REPLACING, ADD ITEMS 415, 416, 417 408 10 FSM Parts Manual Fuel Storage Module Labels 11 FSM Parts Manual Fuel Storage Module Labels Item Qty Quantum Description Part No. 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 LABEL – FILL PANEL, RH 114930 LABEL – FILL PANEL, LH 459 1 114270 LABEL – VENT VALVE 460 1 116552 LABEL – SERIAL NUMBER 12 FSM Parts Manual Accessories PN 114949 1” (25mm) Spacer Kit PN 114954 2” (51mm) Spacer Kit Quantum PN 116544 Insulation Kit Description Part No. 114949 SPACER KIT – 1” (25mm) 114954 SPACER KIT – 2” (51mm) 116544 INSULATION KIT 13 FSM Parts Manual Appendix A - General System Specifications Common Specifications Overall Height ................................................................................................................ 27.6“ (701 mm) Overall Depth (Frame to Cover) .................................................................................... 28.6“ (726 mm) Overall Depth (Frame to Step) ...................................................................................... 33.9“ (861 mm) Distance From Bottom of Assembly to Top of Bottom Step ............................................ 6.7” (169 mm) 25“ X 90“ Fuel Storage Module Overall Length (A) ...................................................................................................... 101.1“ (2568 mm) Distance Between Cover End Cap Bolt Centers (B) ................................................... 98.7“ (2506 mm) Recommended Mounting Area for Cylinder Straps (C)* ................................................ 13.5“ (343 mm) Distance Between Cover End Cap Bolt Center and Cover Support Bracket (D)2 ....... 52.9” (1343 mm) Distance Between Cover End Cap Bolt Center and Cover Support Bracket (D)1 ....... 49.9” (1267 mm) Distance Between Cover End Cap Bolt Center and Cover Support Bracket (D)3 ....... 46.9” (1191 mm) Approximate Fuel Storage Module Weight ...................................................................... 748 lb (339 kg) Approximate Fuel Storage Module Weight (W/Fuel) ..................................................... 1003 lb (455 kg) 25“ X 80“ Fuel Storage Module Overall Length (A) ........................................................................................................ 91.1“ (2314 mm) Distance Between Cover End Cap Bolt Centers (B) ................................................... 88.6“ (2250 mm) Recommended Mounting Area for Cylinder Straps (C)* ................................................ 12.0“ (305 mm) Distance Between Cover End Cap Bolt Center and Cover Support Bracket (D)2 ....... 49.0” (1244 mm) Distance Between Cover End Cap Bolt Center and Cover Support Bracket (D)1 ....... 46.0” (1168 mm) Distance Between Cover End Cap Bolt Center and Cover Support Bracket (D)3 ....... 43.0” (1092 mm) Approximate Fuel Storage Module Weight ..................................................................... 704 lb (319 kg) Approximate Fuel Storage Module Weight (W/Fuel) ...................................................... 930 lb (422 kg) * The cylinder straps may be mounted outside the recommended mounting area but the installation must be approved by a professional engineer. 1,2,3 Reference the centerline for the holes on the right side of the bracket as shown in the illustration above. 14 FSM Parts Manual General System Specifications (Cont) 25“ X 90“ Fuel Storage Module - Slave Overall Length (A) ........................................................................................................ 95.7“ (2431 mm) Distance Between Cover End Cap Bolt Centers (B) .................................................... 93.3“ (2369 mm) Recommended Mounting Area for Cylinder Straps (C)* ................................................ 13.5“ (343 mm) Distance Between Cover End Cap Bolt Center and Cover Support Bracket (D)2 ....... 48.9” (1241 mm) Distance Between Cover End Cap Bolt Center and Cover Support Bracket (D)1 ....... 45.9” (1165 mm) Distance Between Cover End Cap Bolt Center and Cover Support Bracket (D)3 ....... 42.9” (1089 mm) Approximate Fuel Storage Module Weight ......................................................................720 lb (327 kg) Approximate Fuel Storage Module Weight (W/Fuel) .......................................................975 lb (442 kg) 25“ X 80“ Fuel Storage Module - Slave Overall Length (A) ........................................................................................................ 85.8“ (2180 mm) Distance Between Cover End Cap Bolt Centers (B) .................................................... 83.4“ (2118 mm) Recommended Mounting Area for Cylinder Straps (C)* ................................................ 12.0“ (305 mm) Distance Between Cover End Cap Bolt Center and Cover Support Bracket (D)2 ....... 45.9” (1165 mm) Distance Between Cover End Cap Bolt Center and Cover Support Bracket (D)1 ....... 42.9” (1089 mm) Distance Between Cover End Cap Bolt Center and Cover Support Bracket (D)3 ....... 39.9” (1013 mm) Approximate Fuel Storage Module Weight ..................................................................... 672 lb (305 kg) Approximate Fuel Storage Module Weight (W/Fuel) ...................................................... 898 lb (407 kg) * The cylinder straps may be mounted outside the recommended mounting area but the installation must be approved by a professional engineer. Reference the centerline for the holes on the right side of the bracket as shown in the illustration above. 1,2,3 15 FSM Parts Manual General System Specifications (Cont) 25“ X 60“ Fuel Storage Module Overall Length (A) ........................................................................................................ 72.6“ (1843 mm) Distance Between Cover End Cap Bolt Centers (B) ................................................... 70.3“ (1779 mm) Recommended Mounting Area for Cylinder Straps (C)* .................................................. 9.0“ (229 mm) Approximate Fuel Storage Module Weight ..................................................................... 570 lb (259 kg) Approximate Fuel Storage Module Weight (W/Fuel) ...................................................... 736 lb (334 kg) 25“ X 60“ Fuel Storage Module – Slave Overall Length (A) ........................................................................................................ 67.1“ (1705 mm) Distance Between Cover End Cap Bolt Centers (B) ................................................... 64.7“ (1643 mm) Recommended Mounting Area for Cylinder Straps (C)* .................................................. 9.0“ (229 mm) Approximate Fuel Storage Module Weight ...................................................................... 482 lb (219 kg) Approximate Fuel Storage Module Weight (W/Fuel) ....................................................... 651 lb (295 kg) * The cylinder straps may be mounted outside the recommended mounting area but the installation must be approved by a professional engineer. 16 FSM Parts Manual Notes: 17 FSM Parts Manual Notes: 18 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. Revision E (1/26/16) – Updated Upper and Lower Cover information, O-Ring part number, parts ordering information, technical assistance, fill receptacle part numbers, and added general specifications to Appendix A. 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. 2016 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 [email protected]