Gen 1 CNG Frame Mount FSM Parts Manual

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 QTParts@qtww.com
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
info@qtww.com