6

replacement foam cap

n/a

7

Swagelok® Snoop® or similar leak detection fluid

leak check repair

Procedure
1. Remove system covers and shields as needed to access cylinder dome.
2. Remove any tube fittings that would prevent a new cap from being installed. Alternatively, cut cap into a
maximum of two pieces to install the cap with the plumbing in place.
3. Remove any loose foam cap remnants by hand.
NOTICE
Do not remove any adhesive as this will likely cause damage to the cylinder.
WARNINGI
If there is any damage to the cylinder dome the cylinder must be condemned.
4. Clean dome area with a soft cloth or disposable wipe and IPA. Wipe area until cleaning cloths or wipes are
clean after use. Allow time to dry.
5. Prepare adhesive per manufacturer’s instructions by loading adhesive pack onto dispenser then attaching
mixing nozzle.
6. Apply 1-in x 3/8-in (25.4 mm x 0.375 mm) thick dots of adhesive inside the dome at QTY: 4 evenly spaced
positions.
7. Working quickly, align cap so it is centered on the boss and press the cap onto the cylinder end.
NOTICE Apply pressure for a minimum of 10 seconds before releasing.
8. Re-install any tube fittings that were disassembled.
9. Wait 24 hours for the adhesive to fully cure.
10. Fill cylinder and leak check any tube fittings that were re-installed.

Neck Mount Block Replacement
One-Piece Block
Tools and Materials
Item Description

Purpose

1

lifting sling w/ load rating exceeding cylinder weight

support cylinder

2

replacement mount block

n/a

3

isopropyl alcohol (IPA)

remove oils from cylinder surface

4

cleaning cloths or wipes

prepare cylinder surface

5

Swagelok® Snoop® or similar leak detection fluid

leak check repair

Procedure
1. Remove system covers and shields as needed to access the mount block.
2. Remove all tube fittings (if present) from the adapter, valve, or PRD.
3. If it inhibits the removal of the mount block, remove valve or PRD.
4. Support cylinder with a lifting sling near the replacement end. Figure 2
sling
cylinder

Figure 2. Cylinder supported with a sling

5. Remove mount block.
6. Clean cylinder boss with a soft cloth or disposable wipe and IPA. Wipe boss until cleaning cloths or wipes are
clean after use.
WARNINGI
Inspect boss for wear; refer to Cylinder Inspection Manual for criteria.
7. Install new block; torque mount bolts to fuel system OEM specifications.
8. Remove lifting sling.
9. Reinstall valve or PRD and tube fittings.
10. Fill cylinder and leak check any connections that were made.

Two-Piece Block
Tools and Materials
Item Description

Purpose

1

lifting sling w/ load rating exceeding cylinder weight

support cylinder

2

replacement mount blocks

n/a

3

isopropyl alcohol (IPA)

remove oils from cylinder surface

4

cleaning cloths or wipes

prepare cylinder surface

5

Swagelok® Snoop® or similar leak detection fluid

leak check repair

Procedure
1. Remove system covers and shields as needed to access the mount blocks.
2. Support cylinder with lifting sling near the replacement end. Figure 2
3. Remove neck mount block.
4. Clean cylinder boss with a soft cloth or disposable wipe and IPA. Wipe the boss until the cleaning cloths or
wipes are clean after use.
WARNINGI
Inspect boss for wear; refer to Cylinder Inspection Manual for criteria.
5. Install new mount blocks; torque mount bolts to fuel system OEM specifications.
6. Remove lifting sling. Figure 2

Neck Mount Block Bushing Replacement
Tools and Materials
Item Description

Purpose

1

lifting sling w/ load rating exceeding cylinder weight

support cylinder

2

replacement bushing

n/a

3

isopropyl alcohol (IPA)

remove oils from cylinder surface

4

cleaning cloths or wipes

prepare cylinder surface

5

Swagelok® Snoop® or similar leak detection fluid

leak check repair

Procedure
1. Remove system covers and shields as needed to access the mount block bushing.
2. Remove all tube fittings from the adapter or PRD (if present).
3. Remove PRD if it inhibits the removal of the mount block bushing.
4. Support cylinder with lifting sling near the sliding end. Figure 2
5. Remove the mount block and bushing. If the bushing is secured to the mount block by a retaining ring and
plate, remove them (with flat-head screwdriver) to release the bushing.
6. Clean cylinder boss with a soft cloth or disposable wipe and IPA. Wipe boss until cleaning cloths or wipes are
clean after use.
WARNINGI
Inspect boss for wear; refer to Cylinder Inspection Manual for criteria.

7. Install the new bushing into the mount block and slide the block assembly onto the boss. Torque mount bolts
to fuel system OEM specifications.
8. Remove lifting sling. Figure 2
9. If previously removed: reinstall PRD and tube fittings.
10. Fill cylinder and leak check any connections that were made.

Strap Bolt Replacement
Refer to Strap Rubber Pad Replacement (below).

Strap Assembly Replacement
Tools and Materials
Item Description

Purpose

1

lifting sling w/ load rating exceeding cylinder weight

support cylinder

2

replacement strap assembly

n/a

3

clean water and mild detergent

remove oils from cylinder surface

4

cleaning cloths

prepare cylinder surface

5

Swagelok® Snoop® or similar leak detection fluid

leak check repair

Procedure
1. Remove system covers and shields as needed to access the cylinder and strap assembly.
2. Remove all tube fittings from the valve, adapter, or PRD (if present) near the strap assembly to be replaced.
3. Support cylinder with lifting sling near the strap assembly to be replaced. Figure 2
4.
5.
6.
7.

Remove the strap bolt that tightens the rubber pad to the cylinder.
Remove bolts connecting strap assembly to the fuel system frame or vehicle.
Work old strap assembly off the cylinder end. Slightly lifting the cylinder by the sling may aid this process.
Clean cylinder section that will contact the new strap assembly using water mixed with a mild detergent. Rinse
thoroughly with water after cleaning.
WARNINGI
Inspect cylinder for wear; refer to Cylinder Inspection Manual for criteria.
8. Install new strap assembly by moving it into place and bolting it to the fuel system frame or vehicle. Torque
bolts to fuel system OEM specification.
9. Install strap bolt to secure rubber pad against cylinder; torque strap bolts to strap DP document
specifications.
10. Remove lifting sling. Figure 2
11. Reinstall tube fittings.
12. Fill cylinder and leak check any connections that were made.

Strap Rubber Pad Replacement
Tools and Materials
Item Description

Purpose

1

lifting sling w/ load rating exceeding cylinder weight

support cylinder

2

replacement rubber pad and strap bolt

n/a

3

clean water and mild detergent

remove oils from cylinder surface

4

cleaning cloths

prepare cylinder surface

5

Swagelok® Snoop® or similar leak detection fluid

leak check repair

Procedure
1. Remove system covers and shields as needed to access the cylinder and strap assembly.
2. Support cylinder with lifting sling near the rubber pad to be replaced. Figure 3
sling
cylinder

bracket / strap assembly

Figure 3. Cylinder end supported with a sling

3. Remove the strap bolt that tightens the rubber pad to the cylinder.
4. Remove old rubber pad and discard.
5. Clean cylinder section that will contact the new rubber pad using water mixed with a mild detergent. Rinse
thoroughly with water after cleaning.
WARNINGI
Inspect cylinder for wear; refer to Cylinder Inspection Manual for criteria.
6. Install new rubber pad. Figure 4
NOTICE The use of water mixed with mild detergent may ease the installation process.
NOTICE
Lifting the cylinder with a lifting sling may be necessary if replacing the rubber on the base of the strap.
This requires removal of tube fittings from the valve, adapter, or PRD (if present).

cylinder side

strap side

Figure 4. New rubber strap material; ribbed side must be installed against cylinder.

7. Install new strap bolt to secure rubber pad against cylinder; torque bolt to value specified in strap DP
document.
8. If applicable: remove lifting sling. Figure 3
9. If applicable: Reinstall tube fittings.
10. Fill cylinder and leak check any connections that were made.

Label Replacement

Defueling the fuel system is not required for this replacement procedure.
NOTICE Contact Hexagon Agility for replacement label.
Tools and Materials
Item Description

Purpose

1

isopropyl alcohol (IPA)

remove oils from cylinder surface

2

latex or nitrile gloves

protect skin and prevent fuel system contamination

3

cleaning cloths or wipes

prepare cylinder surface

4

replacement label

n/a

5

Optional: squeegee

apply label

Procedure
1. Remove system covers and shields as needed to access cylinder label area.
2. Remove any remnants of the damaged or illegible label.
3. Clean label area with a soft cloth or disposable wipe and IPA. Wipe area until cleaning cloths or wipes are
clean after use. Allow time to dry.
4. Remove backing from new label and position label on cylinder so it is visible for inspection.
5. Press label against cylinder. Working from one edge to the other, use a squeegee (or equivalent) to remove
any bubbles.