Reviewers Note: Words/phrases in blue will be links to specific diagnostic procedures when this document is published in Freshdesk.

CNG Cylinder, Cylinder Component, and Mount Removal & Replacement Manual

DSM.0086 Ver. 3.0 October 30, 2023
Table of Contents
Introduction
About this Document
Safety
In Case of Emergency
General Safety Precautions
Warning Messages and Symbols Used in this Document
Before Proceeding
Cylinder and Component Replacement Procedures
Preparation
Cylinder Replacement
Electric Solenoid Valve Replacement
PRD Replacement
Plug Replacement
Adapter Replacement
O-Ring Removal and Replacement
Foam Cap Replacement
Neck Mount Block Replacement
One-Piece Block
Two-Piece Block
Neck Mount Block Bushing Replacement
Strap Bolt Replacement
Strap Assembly Replacement
Strap Rubber Pad Replacement
Label Replacement

Reviewers Note: Words/phrases in blue will be links to specific diagnostic procedures when this document is published in Freshdesk.

Introduction
About this Document
Procedures in this document contain specific information pertaining to the replacement of Type 4 compressed
natural gas (CNG) cylinders designed and manufactured by Hexagon® Agility®.* These instructions should not
be applied to cylinders made by other manufacturers.**
This document also contains specific information pertaining to the replacement of cylinder components and
mounts in fuel systems designed and manufactured by Hexagon Agility and/or component suppliers. These
instructions should not be applied to fuel systems made by other manufacturers.**
It is the responsibility of the vehicle OEM or third party installer to provide this manual to the appropriate
personnel and to ensure its accessibility. Appropriate personnel includes, but is not limited to, those who are
responsible for cylinder repair and replacement.
A thorough understanding of the information provided in this manual is required for the safe cylinder replacement.
If further information is needed or questions arise, contact Hexagon Agility.
Hexagon Agility endeavors to maintain a comprehensive and accurate product and service information. We reserve the right to make changes at any time
to manuals and other materials. Please contact Hexagon Agility FleetCare to ensure you have the latest version.

*Applies to cylinders labeled under Agility Fuel Solutions, Hexagon Lincoln, and Lincoln Composites
**Consult component original equipment manufacturer (OEM) documents for cylinders and components made by other manufacturers.

Safety
In Case of Emergency
WARNING
In the event of an emergency, call 9-1-1, and evacuate the area.
Information for first responders may be found in Hexagon Agility publication ENP-084.

General Safety Precautions
Always use proper personal protective equipment (PPE) when working on CNG cylinders, fuel systems, and
vehicles.
Required PPE includes but is not limited to the following items:
1.
2.
3.
4.
5.
6.
7.

safety glasses
hard hat
work gloves
When specified: nitrile or latex gloves
steel-toed shoes
high-visibility vest
fall arrestment harness

Warning Messages and Symbols Used in this Document
WARNING
WARNING indicates a hazardous situation which, if not avoided, could result in death or serious injury.
NOTICE sssssssssssssss
NOTICE is used to address practices not related to physical injury, such as best practices or tips to help an
operation or procedure go smoothly and prevent equipment damage.

Reviewers Note: Words/phrases in blue will be links to specific diagnostic procedures when this document is published in Freshdesk.

Before Proceeding
Contact fuel system OEM for replacement parts, repair instructions, and specifications.
WARNING G
Before replacing cylinder or mounting components, defuel the fuel system and verify system is empty.

Cylinder and Component Replacement Procedures
Preparation
1. Open or remove any fuel system doors, access panels, or covers.

2. Clean the area of damage prior to performing any repair.
NOTICE EEEEEEEEEEEEEEEEEEEEEEEEE
Hexagon Agility recommends washing cylinder(s) by hand with water or a mixture of water and mild
detergent. If using detergent, ensure cylinder and surrounding components are thoroughly rinsed with
water.
NOTICE Never use a high-pressure washer or steam cleaner on cylinder surface/system components.
WARNING Never use a steam cleaner on or near pressure relief devices (PRDs) or trigger lines.

Reviewers Note: Words/phrases in blue will be links to specific diagnostic procedures when this document is published in Freshdesk.

Cylinder Replacement
Tools and Materials
Item Description

Purpose

1

QTY: 2 lifting slings w/ load rating exceeding cylinder
weight

remove / replace cylinder

2

replacement cylinder

n/a

3

Strap mount cylinders only: specified rubber pad

rubber pad must be replaced with cylinder

4

O-ring lube, p/n 69000576

required for proper O-ring seal

5

If required: O-rings for fittings and adapters

maintain seal

6

Swagelok® Snoop® or similar leak detection fluid

leak check repair

Procedure
1. Contact fuel system OEM for instructions on how to access the cylinder.
2. Defuel fuel system.
3. Remove all tube fittings from cylinder adapters, valves, plugs, and/or PRDs.
4. Support each end of the cylinder with lifting slings. Figure 1
slings
cylinder

Figure 1. Cylinder supported with two lifting slings

5. Disassemble mounting blocks or straps to allow cylinder to be removed.
WARNING D
If mounting straps are used, the rubber pad on the strap must be removed and replaced.
6. Lift cylinder out of fuel system, set cylinder aside, and remove lifting slings for use in the next step.
7. Lift new cylinder from packaging using lifting slings and position cylinder within the fuel system. Figure 1
8. Secure cylinder using mounting blocks or straps. RECOMMENDED: Replace block or strap hardware.
9. Replace any O-rings. Refer to O-ring Replacement.
10. Install valve, PRD, adapter, and/or plug into new cylinder as needed. Torque all fittings to specified value
[see hardware design parameters (DP) document.]
WARNING D
Never reinstall used valves and PRDs on new cylinders.
11. Rotate cylinder to required orientation to match fuel system plumbing. Torque mounting bolts to fuel
system OEM specification.
12. Inspect tube fittings and replace if necessary before reinstalling.
13. Fill cylinder and leak check any connections that were made.

Reviewers Note: Words/phrases in blue will be links to specific diagnostic procedures when this document is published in Freshdesk.

Manual Cylinder Valve Replacement
Tools and Materials
Item Description

Purpose

1

replacement valve

n/a

2

OEM-specialized valve installation tool

valve removal and replacement

3

O-ring lube, p/n 69000576

required for proper O-ring seal

4

If required: O-rings for fittings and adapters

maintain seal

5

Swagelok® Snoop® or similar leak detection fluid

leak check repair

Procedure
1. Defuel fuel system.
2. Remove system covers and shields as needed to access cylinder valve.
3. Remove all tube fittings from valve.
4. Remove valve using the OEM-specified installation tool.
5. Install valve O-ring on new valve with the shipping cap* in place to protect valve threads from damaging
O-ring. Refer to O-Ring Replacement.
6. Install new valve using the OEM-specified installation tool. Torque valve to OEM specifications (see valve
DP document).
7. Inspect tube fittings and replace if necessary before reinstalling in the new valve.
8. Fill cylinder and leak check the tube fittings and valve.
*If a cap is not available, cover valve threads with electrical tape or similar wrap to protect new O-ring.

Electric Solenoid Valve Replacement
Refer to Electric Solenoid Valve Replacement.

Reviewers Note: Words/phrases in blue will be links to specific diagnostic procedures when this document is published in Freshdesk.

PRD Replacement
Tools and Materials
Item Description

Purpose

1

replacement PRD

n/a

2

O-ring lube, p/n 69000576

required for proper O-ring seal

3

If required: O-rings for fittings and adapters

maintain seal

4

Swagelok® Snoop® or similar leak detection fluid

leak check repair

Procedure
1. Defuel fuel system.
2. Remove system covers and shields as needed to access cylinder PRD.
3. Remove all tube fittings from PRD.
4. Remove PRD.
5. If PRD is installed directly into the cylinder, install the PRD O-ring. Refer to O-Ring Replacement.
6. Install new PRD. Inspect tube fittings and replace if necessary before reinstalling in the new PRD. Torque /
tighten all connections to OEM specifications (see PRD DP document).
7. Fill cylinder and leak check tube fittings and PRD.

Plug Replacement
Tools and Materials
Item Description

Purpose

1

replacement plug

n/a

2

O-ring lube, p/n 69000576

required for proper O-ring seal

3

If required: O-rings for fittings and adapters

maintain seal

4

Swagelok® Snoop® or similar leak detection fluid

leak check repair

Procedure
1. Defuel fuel system.
2. Remove system covers and shields as needed to access the cylinder plug.
3. Remove plug.
4. Install a new O-ring onto new plug. Refer to O-Ring Replacement.
5. Install new plug hand tight. Torque plug to OEM specifications (see plug DP document).
6. Fill cylinder and leak check plug.

Reviewers Note: Words/phrases in blue will be links to specific diagnostic procedures when this document is published in Freshdesk.

Adapter Replacement
Tools and Materials
Item Description

Purpose

1

replacement adapter

n/a

2

O-ring lube, p/n 69000576

required for proper O-ring seal

3

If required: O-rings for fittings and adapters

maintain seal

4

Swagelok® Snoop® or similar leak detection fluid

leak check repair

Procedure
1. Defuel fuel system.
2. Remove system covers and shields as needed to access the cylinder adapter.
3. Remove all tube fittings or PRDs (if present) from the adapter.
4. Remove adapter from cylinder.
5. Install a new O-ring onto new adapter. Refer to O-Ring Replacement.
6. Install new adapter hand tight and torque it to the specified value (see adapter DP document).
7. Re-install tube fittings or PRDs (if present) into new adapter.
8. Fill cylinder and leak check tube fittings, adapter, and PRD (if present).

O-Ring Removal and Replacement
Refer to O-Ring Replacement.

Reviewers Note: Words/phrases in blue will be links to specific diagnostic procedures when this document is published in Freshdesk.

Foam Cap Replacement
WARNINGi
If there is evidence of impact damage on the foam cap, remove cylinder from service and contact
Hexagon Agility.
Tools and Materials
Item Description

Purpose

1

isopropyl alcohol (IPA)

remove oils from cylinder surface

2

cleaning cloths or wipes

Prepare cylinder surface

3

latex or nitrile gloves

protect skin

4

adhesive kit, p/n 240332-01

adhere foam cap

5

dispensing gun, p/n 240338-01

apply adhesive