NHTSA ID Number: 10227647
Manufacturer Communication Number: ENP-728
TSB/Document Date: 2022-12-12
Summary
Edits to this Operation Manual include: ADDED: Severe Duty and Normal Duty vehicle service type definitions. ADDED: Severe Duty interval for HP fuel filter element replacement. CHANGED: kPa and MPa units to bar REVISED: Figure 35 UPDATED: CNG FS inspection interval to every year UPDATED: Hexagon branding and contact information DELETED: HP fuel filter (Manifilter) drain interval from Maintenance table. CORRECTED: HP fuel filter (Manifilter) element change interval CHANGED: HP fuel filter to ?Manifilter? throughout CORRECTED: ?shut off? to ?shutoff;? ?high pressure? to ?high-pressure; ?low pressure? to ?low-pressure? throughout
(Printed and Downloaded Copies are Uncontrolled)
CNG Fuel System Operation Manual
FMM with Manifilter
Covers Type 4 eight-cylinder systems equipped with the following Hexagon® Agility® assemblies:
Fuel Management
Module (FMM) p/ns
Roof
Mount
(RM) p/ns
20860000
25518000
Roof Mount, 155 DGE, 2084 L, 8 Tanks, Type 4
manual
20860500
25519000
Roof Mount, 155 DGE, 2081 L, 8 Tanks, Type 4
electric solenoid
20861000
25520000
Roof Mount, 185 DGE, 2474 L, 8 Tanks, Type 4
manual
20861500
25521000
Roof Mount, 185 DGE, 2468 L, 8 Tanks, Type 4
electric solenoid
20862500
25522000
Roof Mount, 126 DGE, 1657 L, 8 Tanks, Type 4
manual
20862600
25523000
Roof Mount, 126 DGE, 1657 L, 8 Tanks, Type 4
electric solenoid
Cylinder
Valve Type
Description
20863500
ENP-728 REV B
November 23, 2022
Hexagon® Agility® Fuel Solutions. ©2022. All Rights Reserved.
Gillig
CNG Type 4 Eight Cylinder System Operation Manual
Table of Contents
Tables and Figures ...................................................................................................................................................... 4
Preface ........................................................................................................................................................................ 6
Acronyms ..................................................................................................................................................................... 6
1. Safety....................................................................................................................................................................... 7
1.1. Warning Messages and Symbols Used in This Document .............................................................................. 7
1.2. Qualified Personnel .......................................................................................................................................... 8
1.3. Safety Equipment ............................................................................................................................................. 8
1.5. CNG Vehicle Safety Precautions ..................................................................................................................... 9
1.6. Codes and Compliances ................................................................................................................................ 10
1.7. First Responder Guide ................................................................................................................................... 10
1.7.1. General Information ................................................................................................................................. 10
1.7.2. Vehicle Fire Procedures .......................................................................................................................... 10
1.7.3. Return to Service Inspection ................................................................................................................... 10
1.7.4. Emergency Manual Shutdown Procedures ............................................................................................. 11
1.7.5. Emergency Response ............................................................................................................................. 12
2. System Schematics and General Assemblies ...................................................................................................... 13
3. Fuel System Components and Specifications ...................................................................................................... 17
3.1. Fuel Specifications.......................................................................................................................................... 17
3.2. Superstructure ................................................................................................................................................ 17
3.3. Fuel Management Module .............................................................................................................................. 17
3.4. Filters .............................................................................................................................................................. 18
3.4.1. High-pressure Fuel Filter ......................................................................................................................... 18
3.4.2. Low-pressure Fuel Filter .......................................................................................................................... 18
3.5. Supply Solenoid Valve (SSV) ........................................................................................................................ 19
3.5.1. Supply Solenoid Valve (SSV) Principles of Operation ............................................................................ 19
3.6. Pressure Regulator ......................................................................................................................................... 19
3.7. Cylinders ......................................................................................................................................................... 19
3.8. Valves ............................................................................................................................................................. 20
3.8.1. Bleed Valve .............................................................................................................................................. 20
3.8.2. Check Valve ............................................................................................................................................. 20
3.8.3. Defuel Valve ............................................................................................................................................ 20
3.8.4. 1/4-turn Manual Shutoff Valve ................................................................................................................. 20
3.8.5. Manual Cylinder Valve............................................................................................................................. 20
3.8.6. Electric Solenoid Cylinder Valve ............................................................................................................. 21
3.9. Pressure Relief Devices (PRDs) .................................................................................................................... 21
3.9.1. Valve PRD ............................................................................................................................................... 21
3.9.2. Remote PRD............................................................................................................................................ 21
3.10. Fuel Fill and Defuel Receptacles.................................................................................................................. 22
3.11. Fittings and Connections .............................................................................................................................. 23
3.11.1. Tubing .................................................................................................................................................... 23
3.11.2. Fittings ................................................................................................................................................... 23
3.11.3. Tube and Fitting Installations ................................................................................................................ 23
3.11.4. Fitting Safety Considerations................................................................................................................. 23
4. Operation and Maintenance .................................................................................................................................. 24
ENP-728 REV B November 23, 2022
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Gillig CNG Type 4 Eight Cylinder System Operation Manual
4.1. Inspecting Components .................................................................................................................................. 24
4.2. Fuel System Maintenance .............................................................................................................................. 25
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
4.3.6. Repairing a Leak...................................................................................................................................... 28
4.4. Starting Vehicle............................................................................................................................................... 28
4.5. Depressurizing CNG System Tubing ............................................................................................................. 28
4.7. Maintaining High-Pressure Filter .................................................................................................................... 29
4.7.1. Draining the Manifilter Assembly ............................................................................................................. 29
4.7.2. Replacing the HP Fuel Filter Element ..................................................................................................... 30
4.8. Maintaining Low-Pressure Filter ..................................................................................................................... 31
4.8.1. Low-Pressure Filter Replacement and Service ....................................................................................... 31
4.8.2. Draining LP Filter & Replacing the LP Filter Housing ............................................................................. 31
4.9. Supply Solenoid Valve .................................................................................................................................... 32
4.10. Cylinders ....................................................................................................................................................... 33
4.10.1. Inspecting Cylinders .............................................................................................................................. 33
4.10.2. Cylinder Venting Procedure................................................................................................................... 33
4.11. Valve Maintenance ....................................................................................................................................... 33
4.12. Pressure Relief Devices (PRDs) .................................................................................................................. 33
4.12.1. PRD Visual Inspection ........................................................................................................................... 33
4.12.2. PRD Vent Line Visual Inspection .......................................................................................................... 33
4.13. Fill and Defuel Receptacles .......................................................................................................................... 35
4.13.1. Receptacle Maintenance ....................................................................................................................... 35
4.13.2. Transit (Fast) Fill Freeze-Up.................................................................................................................. 35
5. Defueling Preparation and Procedures ................................................................................................................. 36
5.1. Basic Rules for Defueling ............................................................................................................................... 36
5.2. Defueling Requirements ................................................................................................................................. 36
5.2.1. Vent to Atmosphere ................................................................................................................................. 36
5.2.2. Compressor Transfer ............................................................................................................................... 36
5.2.3. Return to Supply ...................................................................................................................................... 36
5.3. A Typical Venting Facility ............................................................................................................................... 36
5.3.1. Venting Facility Minimum Equipment Figure 35 ...................................................................................... 38
5.4. Defueling Procedure ....................................................................................................................................... 39
5.4.1. Confirm All Cylinder Valves are Open ......................................................................................................... 39
5.4.2. Defuel Nozzle Operation ............................................................................................................................. 39
5.5. Removing CNG Cylinders from Service ......................................................................................................... 43
6. Troubleshooting ..................................................................................................................................................... 44
7. Warranty and Contact Information ........................................................................................................................ 47
Proprietary Statement................................................................................................................................................ 47
Trademark Notice ...................................................................................................................................................... 47
ENP-728 REV B November 23, 2022
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Gillig CNG Type 4 Eight Cylinder System Operation Manual
Tables and Figures
Table 1. Revision level
5
Figure 1. CNG blue diamond
10
Figure 2. Emergency shutdown procedure
11
Figure 3. Emergency response procedure
12
Figure 4. Electrical schematic
13
Table 2. Connector pin out
13
Table 3. Electrical BOM
13
Figure 5. CNG system schematic
14
Table 4. CNG system components (refer to Figure 5)
14
Figure 6. Fuel management module (FMM) components (refer to Table 5)
15
Table 5. FMM components. (refer to Figure 6)
16
Figure 7. Roof mounted CNG storage
17
Figure 8. FMM face plate components
17
Figure 9. FMM components, rear view
17
Figure 10. Remote fill option components
17
Figure 11. Manifilter high-pressure filter components
18
Figure 12. Low-pressure filter components
18
Figure 13. Supply solenoid valve (SSV)
19
Figure 14. Pressure regulator
19
Figure 15. Bleed valve location
20
Figure 16. Check valve
20
Figure 17. Defuel valve
20
Figure 18. 1/4-turn manual shutoff valve
20
Figure 19a. Manual cylinder valve
20
Figure 19b. Electric solenoid cylinder valve
21
Figure 20a. Remote PRD
21
Figure 20b. Valve PRD
21
Figure 21. Fill receptacles
22
Figure 22. Optional remote transit fuel fill panel
22
Figure 23. Always use two wrenches when loosening or tightening a fitting
23
Table 6. Maintenance schedule
25
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
27
Figure 27. Bleed valve location within the FMM
29
Table 7a. Manifilter element replacement intervals
29
Figure 28. Manifilter assembly FMM location and drain plug
30
Table 7b. Manifilter torque specifications
30
Figure 29. Manifilter components
30
Figure 30. LP fuel filter drain cock location
31
Figure 31. Supply solenoid valve location
32
ENP-728 REV B November 23, 2022
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Gillig CNG Type 4 Eight Cylinder System Operation Manual
Table 8. Supply solenoid valve (SSV) troubleshooting
32
Figure 32. Cylinder plug end
34
Figure 33. Cylinder valve end
34
Figure 34. FMM fill receptacles
35
Figure 35. Required defueling connections and typical atmospheric venting facility equipment diagram
38
Figure 36. BDN defueling nozzle
39
Figure 37. FMM operation
40
Figure 38. Ground wire clip must be connected to ground on the vehicle
40
Figure 39. FMM defueling valves and gauges
40
Figure 40. FMM 1/4-turn manual shut off valve in OPEN/ON position.
40
Figure 41. Defuel receptacle, dust cap
40
Figure 42. Use a pick or small screwdriver to remove defuel receptacle O-ring
41
Figure 43. Brass insert is located inside BDN nozzle lever
41
Figure 44. Brass insert, defuel receptacle
41
Figure 45. O-ring, defuel receptacle
41
Figure 46. Before attaching BDN nozzle to defuel receptacle, verify valve handle is turned to VENT
41
Figure 47. Pull on BDN nozzle cotter pin to retract lever
41
Figure 48. BDN nozzle, receiver
42
Figure 49. BDN nozzle, lever, FMM defuel receptacle
42
Figure 50. Pull on BDN nozzle gently
42
Figure 51. BDN nozzle valve handle
42
Figure 52. Fuel dispenser defuel valve
42
Table 9. Troubleshooting problems
44
Table 10. Trouble solutions
44
Figure 47. Low-pressure fuel light troubleshooting
45
Figure 48. Gas leak troubleshooting
46
Table 1. Revision level.
--
B
C.Grasso
B. Witt /
J. Wainz
11/23/2022
--
A
C.Grasso
CCG Team
11/13/2020
--
--
B. Witt/C.Grasso
CCG Team
7/27/2020
ECN
REV
AUTHOR
APPROVED
DATE
ENP-728 REV B November 23, 2022
ADDED: §4.2. Fuel System Maintenance §4.2.1. Maintenance
Schedule. SOURCE: ENP-516 REV E.
CHANGED: kPa and MPa units to bar
REVISED: Figure 35
UPDATED: CNG FS inspection interval to every year
UPDATED: Hexagon branding and contact information
DELETED: HP fuel filter (Manifilter) drain interval from
Maintenance table.
CORRECTED: HP fuel filter (Manifilter) element change interval
CHANGED: HP fuel filter to “Manifilter” throughout
CORRECTED: “shut off” to “shutoff;” “high pressure” to “highpressure; “low pressure” to “low-pressure” throughout
UPDATED: Warning & signal word flags and definitions;
REVISED: Figure 5;
RENAMED: “Needle Valve” is now “Defuel Valve;”
ADDED: Cylinder valve images and specs;
REVISED: HP filter maintenance intervals;
DELETED: Draining the HP filter;
DELETED: Draining PRD Vent Lines;
UPDATED: Defueling Preparation and Procedures
Initial release
DESCRIPTION
(Printed and Downloaded Copies are Uncontrolled)
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Gillig CNG Type 4 Eight Cylinder System Operation Manual
Preface
This manual is designed as a supporting document to mechanics and operators trained in the operation
procedures and maintenance of the compressed gas fuel system provided by Hexagon Agility.
No attempt shall be made to fill, install, or maintain this system until this manual and all referenced supporting
documentation have been read and fully understood.
This manual dated 11/23/2022 is an update of ENP-044 to reflect changes in the fuel fill module design; contact
Gillig to obtain ENP-044 for earlier systems. Any information reproduced by Gillig for their use, or that of their
customers and clients, should be drawn from this manual.
Original Equipment Manufacturer (OEM) replacement parts may be obtained by contacting Gillig.
All replacement parts must adhere to the accepted standards and ratings as specified by Hexagon Agility. The usage of any
part that is not approved by Hexagon Agility is not recommended and may compromise the integrity and safety of the system.
Do not remove components from original packaging until absolutely necessary. Any components that are to be reinstalled
must be thoroughly cleaned, inspected, and stored in a satisfactory manner until reinstallation.
Acronyms
AGA
American Gas Association
HP
high-pressure
ANSI
American National Standards Institute
LP
low-pressure
ASM
assembly
MPa
megapascal
BOM
- The world’s #1 fuel additive for both gasoline and diesel...
- A great tune-up in a bottle – treats gasoline, diesel fuel...
- Cleans and lubricates the fuel system, including fuel...
- Improves fuel economy by burning excess exhaust emissions
- Increases power and acceleration by improving fuel flow and...
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TSB/Document ID: ENP-728
Replacement Service Bulletin Number:
MFR Communication Date: 2022-11-23
MFR Internal Campaign ID/Software Version:
Communication Type: Service Bulletin/Repair Instructions
NHTSA Components: EQUIPMENT
MFR Component System:
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