NHTSA ID Number: 10220119
Manufacturer Communication Number: ENP-756
TSB/Document Date: 2022-09-15
Summary
Deleted CNG HP fuel filter (Manifilter) drain interval from Maintenance table.
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- Restores fuel economy
- Stabilizes ethanol
- Maximizes horsepower
- Improves responsiveness
- For use in both gasoline and diesel engines
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TSB/Document ID: ENP-756
Replacement Service Bulletin Number:
MFR Communication Date: 2022-08-03
MFR Internal Campaign ID/Software Version:
Communication Type: Service Bulletin/Repair Instructions
NHTSA Components: FUEL SYSTEM, OTHER:FUEL FILTER
MFR Component System:
MFR Component Subsystem:
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(Printed and Downloaded Copies are Uncontrolled)
CNG Fuel System Operation Manual
FMM with Manifilter
Hexagon® Agility® roof mount 5-cylinder systems
Covers systems equipped with the following Hexagon® Agility® Fuel Management Modules (FMMs) and
fuel storage assemblies:
Fuel Management Module (FMM) p/ns
Roof mount system p/ns
20810000
20814000
20860000
25530000 (manual cylinder valves)
20810500
20814500
20860500
25531000 (electric solenoid cylinder valves)
20811000
20815000
20861000
25533000 (electric solenoid cylinder valves)
20811500
20815500
20861500
25534000 (manual cylinder valves)
20812500
20816500
20862500
25535000 (electric solenoid cylinder valves)
20812600
20816600
20862600
25536000 (electric solenoid cylinder valves)
20813500
20817500
20863500
25537000 (electric solenoid cylinder valves)
20813600
20817600
25538000 (manual cylinder valves)
ENP-756 REV E
August 3, 2022
Hexagon® Agility®. ©2022. All Rights Reserved.
Gillig
CNG Five Cylinder System Operation Manual
Table of Contents
Tables and Figures ...................................................................................................................................... 4
Preface ........................................................................................................................................................ 6
Acronyms .................................................................................................................................................... 7
1. Safety ...................................................................................................................................................... 7
1.1. Qualified Personnel .............................................................................................................................. 8
1.2. Safety Equipment ................................................................................................................................. 8
1.4. CNG Vehicle Safety Precautions .......................................................................................................... 9
1.5. Codes and Compliances .................................................................................................................... 10
1.6. First Responder Guide ....................................................................................................................... 10
1.6.1. General Information ..................................................................................................................... 10
1.6.2. Vehicle Fire Procedures .............................................................................................................. 10
1.6.3. Return to Service Inspection ........................................................................................................ 10
1.6.4. Emergency Manual Shutdown Procedures .................................................................................. 11
1.6.5. Emergency Response ................................................................................................................. 12
2. System Schematics and General Assemblies ........................................................................................ 13
3. Fuel System Components and Specifications ........................................................................................ 18
3.1. Fuel Specifications ............................................................................................................................. 18
3.2. Superstructure.................................................................................................................................... 18
3.3. Fuel Management Module (FMM) ...................................................................................................... 18
3.4. Filters ................................................................................................................................................. 19
3.4.1. High-Pressure Fuel Filter ............................................................................................................. 19
3.4.2. Low-Pressure Fuel Filter.............................................................................................................. 19
3.5. Supply Solenoid Valve ....................................................................................................................... 20
3.5.1. Supply Solenoid Principles of Operation ...................................................................................... 20
3.6. Pressure Regulator ............................................................................................................................ 20
3.7. Cylinders ............................................................................................................................................ 20
3.8. Valves ................................................................................................................................................ 21
3.8.1. Bleed Valve ................................................................................................................................. 21
3.8.2. Check Valve ................................................................................................................................ 21
3.8.3. Defuel Valve ................................................................................................................................ 21
3.8.4. 1/4-Turn Manual Shutoff Valve .................................................................................................... 21
3.8.5. Manual Cylinder Valve ................................................................................................................. 21
3.8.6. Electric Solenoid Cylinder Valve .................................................................................................. 22
3.9. Pressure Relief Devices (PRDs)......................................................................................................... 22
3.11. Fittings and Connections .................................................................................................................. 24
3.11.1. Tubing ....................................................................................................................................... 24
3.11.2. Fittings....................................................................................................................................... 24
3.11.3. Tube and Fitting Installations ..................................................................................................... 24
3.11.4. Fitting Safety Considerations: .................................................................................................... 24
4. Operation and Maintenance................................................................................................................... 25
4.1. Inspecting Components...................................................................................................................... 25
4.2. Maintenance Schedule ....................................................................................................................... 26
4.3. Leaks ................................................................................................................................................. 26
4.3.1. Tubing Bottoming Requirements ................................................................................................. 26
4.3.2. Tightening Fitting Nuts ................................................................................................................. 26
4.3.3. Testing for Leaks ......................................................................................................................... 26
4.3.4. Tightening Leaking Fittings .......................................................................................................... 26
4.3.5. Pressure Test Using an Inert Gas (Nitrogen): .............................................................................. 27
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4.3.6. Repairing a Leak ......................................................................................................................... 28
4.4. Starting Vehicle .................................................................................................................................. 28
4.5. Depressurizing CNG System Tubing .................................................................................................. 29
4.6. Re-Pressurizing System ..................................................................................................................... 29
4.7. Maintaining Manifilter HP fuel filter ..................................................................................................... 30
4.7.1. Draining the Manifilter Assembly.................................................................................................. 30
4.7.2. Replacing the HP Fuel Filter Element .......................................................................................... 31
4.8. Maintaining Low-Pressure Filter ......................................................................................................... 32
4.8.1. Low-Pressure Filter Replacement and Service ............................................................................ 32
4.8.2. Draining LP Filter and Replacing the LP Filter Housing ............................................................... 32
4.9. Supply Solenoid Valve (SSV) ............................................................................................................. 33
4.10. Cylinders .......................................................................................................................................... 34
4.10.1. Inspecting Cylinders .................................................................................................................. 34
4.10.2. Cylinder Venting Procedure ....................................................................................................... 34
4.11. Valve Maintenance ........................................................................................................................... 34
4.12. Pressure Relief Devices (PRDs)....................................................................................................... 34
4.12.1. PRD Visual Inspection ............................................................................................................... 34
4.12.2. Draining Vent Lines ................................................................................................................... 35
4.13. Fill and Defuel Receptacles .............................................................................................................. 37
4.13.1. Receptacle Maintenance ........................................................................................................... 37
4.13.2. Transit (Fast) Fill Freeze-Up ...................................................................................................... 37
5. Defueling Preparation and Procedures .................................................................................................. 38
5.1. Basic Rules for Defueling ................................................................................................................... 38
5.2. Defueling Requirements ..................................................................................................................... 38
5.2.1. Vent to Atmosphere ..................................................................................................................... 38
5.2.2. Compressor Transfer ................................................................................................................... 38
5.2.3. Return to Supply .......................................................................................................................... 38
5.3. A Typical Venting Facility ................................................................................................................... 38
5.3.1. Venting Facility Minimum Equipment Figure 35 ........................................................................... 39
5.4. Defueling Procedure........................................................................................................................... 40
5.4.1. Confirm All Cylinder Valves are Open ............................................................................................. 40
5.4.2. Defuel Nozzle Operation ................................................................................................................. 40
5.5. Removing CNG Cylinders from Service.............................................................................................. 44
6. Troubleshooting ..................................................................................................................................... 45
7. Warranty and Contact Information ......................................................................................................... 48
Proprietary Statement ................................................................................................................................ 48
Trademark Notice ...................................................................................................................................... 48
Appendix A. Special considerations for electric solenoid cylinder valve fuel system defueling. .................. 49
A1. Defueling Method 1: Defuel with Audible Test Method ........................................................................ 49
A2. Defueling Method 2: Defuel Using Valve Disassembly ........................................................................ 52
A3. Defueling When No Battery Power is Available ................................................................................... 53
A4. Solenoid Cylinder Valve Disassembly ................................................................................................. 56
A5. Solenoid Valve Function Test and Cylinder Venting After Valve Disassembly..................................... 60
A6. Solenoid Cylinder Valve Reassembly after Passing Function Test...................................................... 61
A7. Remove and Replace Solenoid Cylinder Valve ................................................................................... 62
A8. Re-orient Cylinder ............................................................................................................................... 63
A9. Solenoid Cylinder Valve Function Tests .............................................................................................. 63
Contact Information ................................................................................................................................... 64
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Tables and Figures
Table 1. Revision level
6
Figure 1. CNG blue diamond decal
10
Figure 2. Emergency shutdown procedure
11
Figure 3. Emergency response procedure - precautions
12
Figure 4. Electrical schematic
13
Table 2. Connector pin out
13
Table 3. Electrical BOM
13
Figure 5. CNG system schematic – electric solenoid cylinder valves
14
Figure 6. CNG system schematic – manual cylinder valves
15
Figure 7. Fuel Management Module (FMM) components, exploded (Refer to Table 4)
16
Table 4. Fuel Management Module (FMM) components (refer to Figure 5)
17
Figure 8. Roof mounted CNG storage
18
Figure 9a. FMM face plate components
18
Figure 9b. FMM components, bottom view
18
Figure 10. Remote fill option components
19
Figure 11. Manifilter high-pressure (HP) fuel filter components
19
Figure 12. Low-pressure (LP) fuel filter components
20
Figure 13. Supply solenoid valve (SSV)
20
Figure 14. Pressure regulator
20
Figure 15. Bleed valve
21
Figure 16. Check valve
21
Figure 17. Defuel valve
21
Figure 18. 1/4-turn manual shutoff valve
21
Figure 19. Manual cylinder valve
21
Figure 20. Electric solenoid cylinder valve
22
Figure 21a. Remote PRD
22
Figure 21b. Remote PRD locations
22
Figure 22a. Fuel fill and defuel receptacles
23
Figure 22b. Optional remote transit fill panel
23
Figure 23. Always use two wrenches when loosening or tightening a fitting.
24
Table 5. Maintenance Schedule
26
Figure 24. Cylinder valve manual shutoff knobs
27
Figure 25. FMM 1/4-turn manual shutoff valve operation
27
Figure 26. FMM, NGV1 defuel receptacle, dust cap
28
Figure 27. Bleed valve location within the FMM
29
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Figure 28. Manifilter FMM location and drain plug
30
Figure 29. Manifilter components
31
Table 6. Manifilter torque specifications
31
Figure 30. LP fuel filter drain cock location.
32
Figure 31. Solenoid valve location in FMM.
33
Table 7. Solenoid valve troubleshooting
33
Figure 32. Cylinder plug end
35
Figure 33a. Cylinder valve end – manual cylinder valves Cylinder plug end
36
Figure 33b. Cylinder valve end – electric solenoid cylinder valves
36
Figure 34. FMM fill receptacles
37
Figure 35. Typical atmospheric venting equipment
39
Figure 36. Fuel transfer hose assembly, p/n 20110011
40
Figure 37. FMM operation
41
Figure 38. Ground wire clip must be connected to ground on the vehicle
41
Figure 39. FMM defueling valves and gauges.
41
Figure 40. FMM 1/4-turn manual shutoff valve (1) in OPEN/ON position
41
Figure 41. Defuel receptacle, dust cap
42
Figure 42. Use a pick or small screwdriver to remove defuel receptacle O-ring
42
Figure 43. Brass insert is located inside BDN nozzle lever
42
Figure 44. Brass insert, defuel receptacle
42
Figure 45. O-ring, defuel receptacle
43
Figure 46. Verify BDN nozzle valve handle is turned to VENT
42
Figure 47. Pull on BDN nozzle cotter pin to retract lever
43
Figure 48. BDN nozzle, receiver
43
Figure 49. BDN nozzle, lever, FMM defuel receptacle
43
Figure 50. Pull on BDN nozzle gently
43
Figure 51. Turn BDN nozzle valve handle to DEFUEL position
43
Figure 52. Always open defuel valve manual handle slowly
43
Table 8. Troubleshooting problems
45
Table 9. Trouble solutions
45
Figure 53. Low-pressure fuel light troubleshooting
46
Figure 54. Gas leak troubleshooting
47
Figure A1. Electric solenoid cylinder valve system valve end view.
49
Figure A2. Fuel Management Module (FMM) components: front view from below
50
Figure A3. Fuel Management Module (FMM) face plate components
50
Figure A4. OMB ESA cylinder electric solenoid valve
56
Figure A5. Solenoid valve manual knob operation
56
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Figure A6. Begin solenoid valve disassembly by removing coil nut from coil
57
Figure A7. Remove solenoid coil from valve stem
58
Figure A8. Use a 25mm wrench to remove solenoid sleeve from valve body
58
Figure A9. Remove plunger and spring from valve stem
59
Figure A10. Disassembled solenoid valve assembly
61
Figure A11. ESA solenoid valve torque tool
62
Table 1. Revision level.
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E
C. Grasso
CCTS Team
08/03/2022
--
D
C.Grasso
CCTS Team
08/01/2022
--
C
C.Grasso
CCTS Team
07/21/2022
--
B
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