ENP-735 – Emer PRD Replacement for Gillig CNG Fuel Systems with Type 4 Cylinders and Manual Cylinder Valves – Agility

SEOCONTENT-START

5. Corrective Action / Procedure
5.1. Preliminary Safety Preparation
1
Set parking brake and
secure vehicle with wheel
chocks (not shown).
2
Attach a lock and tag (not
shown) to block vehicle
ignition.
WHAT
WHAT
WHY
Worker safety.
WHY
Prevent vehicle start during
repair procedure.
3
Secure a safety ladder in
either of the following
locations:
A. Inside bus hatch
opening
B. Rear of bus exterior
WHY WHAT
Worker safety.
ENP-735 REV C 6/7/2020 (Printed and downloaded copies are uncontrolled) 8 of 75
4 1. Open fuel system roof
pod doors (d).
2. Secure fall protection
equipment to facility fall
protection apparatus
(not shown).
If no fall restraint is
present at the facility,
secure fall protection
equipment (not shown)
to fall restraint lanyard
attachment points (2).
3. Secure doors open with
door retention strap (e).
Refer to vehicle OEM
instructions.
Always reattach fall PPE
when resuming work on
the roof mount portion of
the fuel system.
WHY WHAT
Worker safety.
1
2
d
e
ENP-735 REV C 6/7/2020 (Printed and downloaded copies are uncontrolled) 9 of 75
5.2. Prior to defueling
1
Verify all eight cylinder
valves (circled) are open.
WHY WHAT
Ensure cylinders can be
properly defueled.
2 Check high pressure
gauge (3) on fuel
management module
(FMM) (4) to verify amount
of fuel in the system.
IMPORTANT: If vehicle
has no fuel onboard,
proceed to Step 10.
WHY WHAT
4
3
ENP-735 REV C 6/7/2020 (Printed and downloaded copies are uncontrolled) 10 of 75
3 If not already defueled:
Defuel bus according to
local facility regulations
and procedure.
If required: Use defuel
hose kit.
Only trained CNG fuel
systems technicians may
perform system
defueling.
If required: Use
appropriate defuel nozzle
adapter.
4
Relieve any remaining
system pressure by slowly
opening the FMM (4) bleed
valve (b).
WHAT
WHAT
WHY
PRD supply tubes to be
removed are pressurized
“live” lines.
WHY
b
4
ENP-735 REV C 6/7/2020 (Printed and downloaded copies are uncontrolled) 11 of 75
5.3. Remove Emer PRDs
1 1.Use two wrenches to
loosen nut fittings (a) on
each Emer™ PRD (d).
2.Use wrenches to remove
fasteners securing the
following items:
A. P-clip (7)
B. Dual tube clamp (8)
C. Plate (6)
Retain all clips,
clamps, plates and
fasteners for reuse.
▪ Support PRD and PRD
vent assembly while
removing clips and
clamps.
▪ Avoid contact with
cylinders (e) or PRD
supply tube (f).
3. Carefully remove
Emer™ PRDs (d) and
PRD vent tubes (5a)
and (5b) from each PRD
bracket (9) as complete
assemblies.
4. Repeat for all plug end
cylinders on all roof
mount pods.
WHY WHAT
Protect cylinders and PRD
plumbing from damage.
7
6
7
6
NOTE: 85-in. cylinder end of
system shown; 120-in. similar.
d
d
9
9
8
8
a
d
f
e
5a
5b
ENP-735 REV C 6/7/2020 (Printed and downloaded copies are uncontrolled) 12 of 75
2 Use a pair of wrenches to
remove all Emer™ PRDs
(d) from PRD vent tubes
(5a) and (5b).
Dispose of PRD vent
tubes (5a) and (5b)
according to facility
guidelines.
3 Use form FT.0320 (c)
to record the following
data for each Emer™
PRD (d) removed:
A. Date of Manufacture (a)
B. Batch number (b)
WHAT
WHAT
WHY
PRD vent tubes will not be
reused.
WHY
Required for retrofit kit
component and repair
tracking and, if applicable,
installer reimbursement.
5a
d
5b
d
c
a
b
ENP-735 REV C 6/7/2020 (Printed and downloaded copies are uncontrolled) 13 of 75
4 Place all removed Emer™
PRDs in zip lock bag
provided with bulk retrofit
kit shipment.
Place only PRDs from
one vehicle in each zip
lock bag.
Bag must be labeled with
the following:
1. Fleet
2. VIN
3. Fuel system s/n
WHAT
WHY
1. Bag helps prevent PRD
contamination.
2. Agility is collecting all
PRDs removed; return
material authorization
(RMA) instructions
appear below.
ENP-735 REV C 6/7/2020 (Printed and downloaded copies are uncontrolled) 14 of 75
5.4. Install PRD retrofit kits
5.4.1. Kit, Retrofit, Gillig, 85″ tanks PRD Retrofit, p/n 25519030, installation instructions
Always perform installation steps in the order specified.
1 1. Install ferrules (not
visible) and nut (a) from
tee fitting (12), p/n
10200208, on PRD
tube, (13), p/n
25519417.
2. Install ferrules (not
visible) and nut (b) from
tube fitting (14), p/n
10200065, on PRD
tube, (13).
3. Install ferrules (not
visible) and nut (c) from
tee fitting (12), p/n
10200208, on tube
adapter fitting, (17), p/n
10200238.
Refer to Appendix A:
WI.0197 Manual Swaging
of Swagelok Fittings.
WHY WHAT
a
13
b
12
14
c
17 85-in. cylinder pod
ENP-735 REV C 6/7/2020 (Printed and downloaded copies are uncontrolled) 15 of 75
2 1. Install tee fitting (12), p/n
10200208, on PRD
tube, (13).
Tighten fitting finger
tight; fittings will be
tightened at a later step.
2. Install two tube clamp
kits (15), p/n 10701508,
on PRD tube, (13).
3. Insert one 1.5-in. hex
cap screw (a), p/n
10760200-0150, and
one 2.5-in. hex cap
screw (b), p/n
10760200-0120, into
each tube clamp kit (15),
as shown in INSET A.
4. Install one flat washer,
p/n 10761000, and one
flange top nut, p/n
10763000 (not shown)
on each hex cap screw
inserted.
5. Secure clamps (15) at
existing holes (circled)
on PRD bracket (9).
To ease component
installation, leave
fasteners loose.
WHY WHAT
Support PRD vent lines.
13 15
9
12
INSET A
85-in. cylinder pod
ENP-735 REV C 6/7/2020 (Printed and downloaded copies are uncontrolled) 16 of 75
3 Install PRD supply tube
(5c) nut fitting (a) at tee
fitting (12) of PRD tube
(13).
Tighten fitting finger
tight; fitting will be
torqued at a later step.
WHY WHAT
5c
13
12
85-in. cylinder pod
a
ENP-735 REV C 6/7/2020 (Printed and downloaded copies are uncontrolled) 17 of 75
4
Always use a
backing wrench on the
main fitting while using a
wrench to install another
fitting.
1. Install tube adapter
fitting (17), p/n
10200238 on VTI PRD
(16b), p/n 10300513.
Torque fitting (17)
to 26 ft-lbs
(35.25Nm)
2. Install straight fitting
(18), p/n 10200563, on
VTI PRD (16a), p/n
10300513.
3. Install straight fitting
(18), p/n 10200563, on
VTI PRD (16a), p/n
10300513.
Torque fittings (18)
to 18.5 ft-lbs
(25Nm).
4. Install tube fitting (14),
p/n 10200065, on VTI
PRD (16a), p/n
10300513.
Torque fitting (14)
to 45 ft-lbs (61Nm).
WHY WHAT
16a
14 17
18 16b 18
85-in. cylinder pod
ENP-735 REV C 6/7/2020 (Printed and downloaded copies are uncontrolled) 18 of 75
5 1. Install VTI PRD (16a)
assembly inlet fitting (a)
on PRD supply tube
(13) at tee fitting (12).
2. Install VTI PRD outlet
fitting (16b) on straight
fitting (b) on other end of
PRD supply tube (13).
Tighten fittings finger
tight; fittings will be
torqued at a later step.
PRD ports (c) must
be oriented 90°
down from the flow of
system tubing as shown.
WHY WHAT
a b
16a 16b
13
12
85-in. cylinder pod
c c
ENP-735 REV C 6/7/2020 (Printed and downloaded copies are uncontrolled) 19 of 75
6a 1. Install PRD vent tube
(26), p/n 25519026, on
PRD (16a) fitting (a).
Tighten nut fitting finger
tight; fittings will be
tightened at a later step.
2. Slip dual tube clamp (8),
on PRD vent tube (26),
and on PRD vent tube
(5a).
3. Use dual tube clamp (8)
fasteners (not visible) to
secure plate (6) and
PRD vent tube (26), to
PRD bracket (9) at hole
(circled).
4. Slide P-clip on PRD vent
tube (26) and use
existing fastener to
secure P-clip (7) to Pclip
bracket (b).
Tighten fasteners finger
tight; fasteners will be
torqued at a later step.
WHY WHAT
5c
8
7
b
26
a
16a
6
85-in. cylinder pod
ENP-735 REV C 6/7/2020 (Printed and downloaded copies are uncontrolled) 20 of 75
6b 1. Install PRD vent tube
(37), p/n 25519037, on
PRD (16b) fitting (a).
Tighten nut fitting (b)
finger tight; fitting will be
tightened at a later step.
2. Slip tube clamp kit (15),
on PRD vent tube (37).
3. Insert one 1.5-in. hex
cap screw, p/n
10760200-0150, and
one 2.5-in. hex cap
screw, p/n 10760200-
0120, into each tube
clamp kit (15), as shown
in INSET A.
4. Install one flat washer,
p/n 10761000, and one
flange top nut, p/n
10763000 (not shown)
on each hex cap screw
inserted in previous sub
step.
5. Secure PRD vent tube
(37) to PRD bracket (9)
at hole.
Tighten fasteners finger
tight; fasteners will be
torqued at a later step.
WHY WHAT
37
a 15 16b
INSET A
2.5-in. HEX CAP SCREW FACES TOWARD
PRD BRACKET (9) TO SECURE CLAMP
(15) TO PRD BRACKET.
1.5-in. HEX CAP SCREW FACES AWAY
FROM PRD BRACKET TO CAPTURE
CLAMP (15).
15
b
85-in. cylinder pod
ENP-735 REV C 6/7/2020 (Printed and downloaded copies are uncontrolled) 21 of 75
7 1. Install tube clamp
bracket (23), p/n
25519123, on existing
double tube clamp (8)
using the double tube
clamp fasteners (not
shown).
2. Install P-clip (7), p/n
10702147, on PRD vent
tube (37), p/n 25519037,
and secure to bracket
(23), p/n 25519123
using one hex cap
screw, p/n 10760200-
0100, one flat washer,
p/n 10761000, and one
flange top nut, p/n
10761300.
Tighten fasteners finger
tight; fasteners will be
tightened at a later step.
WHY WHAT
System specification.
7
VIEW A
VIEW A
23
23
26
8
37
37
37 6
85-in. cylinder pod
ENP-735 REV C 6/7/2020 (Printed and downloaded copies are uncontrolled) 22 of 75
8a Use two wrenches to
tighten 1/2-in.
Swagelok® fitting
nuts indicated in the
following sequence:
1. (a)
2. (b)
3. (c)
4. (d)
Tighten 1/2-in.
Swagelok® fittings per
Appendix B WI.0441.
WHY WHAT
System specification.
8b Use two wrenches to
tighten SAE / JIC
fitting nuts at the locations
indicated in the following
sequence:
1. (e)
2. (f)
Tighten SAE / JIC fittings
to 45 ft-lbs (61Nm).
WHY WHAT
System specification.
b a 85-in. cylinder pod
d
c
85-in. cylinder pod
f e
ENP-735 REV C 6/7/2020 (Printed and downloaded copies are uncontrolled) 23 of 75
9 Tighten clamp
fasteners at all
clamp locations (circled)
using the following
sequence:
1. (a)
2. (b)
3. (c)
4. (d)
5. (e)
6. (f)
Tighten fasteners to 8 ftlbs
(11Nm).
WHY WHAT
System specification.
Proper tightening
sequence is crucial to
system performance.
85-in. cylinder pod
a b c
d
e
f
ENP-735 REV C 6/7/2020 (Printed and downloaded copies are uncontrolled) 24 of 75
10 1. Verify clearance
between PRD vent
tubes (a) and live high
pressure PRD vent tubes
(b) is 3/8-in. minimum.
2. Verify clearance
between all system
plumbing and cylinders (c)
is 3/8-in. minimum.
If required: Adjust tube
clips and clamps as
necessary and repeat
Step 10.
WHY WHAT
Prevent fuel line damage.
b
b
a
c
a
b
PLUG END
A
VALVE END
A
85-in. cylinder pod
ENP-735 REV C 6/7/2020 (Printed and downloaded copies are uncontrolled) 25 of 75
11 1. Install ferrules (not
visible) and nut (a) from
tee fitting (12), p/n
10200208, on PRD vent
tube, (13), p/n
25519417.
2. Install ferrules (not
visible) and nut (b) from
tube fitting (14), p/n
10200065, on straight
end of PRD vent tube
(13).
3. Install ferrules (not
visible) and nut (c) from
tee fitting (12), p/n
10200208, on tube
adapter fitting, (17), p/n
10200238.
Refer to Appendix A:
WI.0197 Manual Swaging
of Swagelok Fittings.
4. Install tee fitting (12),
p/n 10200208, on PRD
vent tube (13), p/n
25519417.
Tighten fitting finger
tight; fittings will be
tightened at a later step.
WHY WHAT
b
13
12
14
a
12
17 c
85-in. cylinder pod
ENP-735 REV C 6/7/2020 (Printed and downloaded copies are uncontrolled) 26 of 75
12 1. Install two tube clamp
kits (15), p/n 10701508,
on Tube, Formed, HP
Fuel, 1/2-in. X .049 -in.,
Tee to PRD, (13), p/n
25519417.
2. Insert one 1.5-in. hex
cap screw, p/n
10760200-0150, and
one 2.5-in. hex cap
screw, p/n 10760200-
0120, into each tube
clamp kit (15), as shown
in INSET A.
3. Install one flat washer,
p/n 10761000, and one
flange top nut, p/n
10763000 (not shown)
on each hex cap screw
inserted in previous sub
step.
4. Secure PRD vent tube
(13) to PRD bracket (9)
at holes (circled).
To ease component
installation, do not
tighten fasteners
completely; fasteners
will be torqued at a later
step
WHY WHAT
Support PRD vent lines.
15
13
9
INSET A
15
2.5-in HEX CAP SCREW FACES TOWARD PRD BRACKET
(9) TO SECURE CLAMP (15) TO PRD BRACKET.
1.5-in HEX CAP SCREW FACES AWAY FROM
PRD BRACKET (9) TO CAPTURE CLAMP (15).
85-in. cylinder pod
ENP-735 REV C 6/7/2020 (Printed and downloaded copies are uncontrolled) 27 of 75
13 Install PRD supply tube (5d)
on PRD supply tube (13) at
tee fitting (12).
Tighten fitting finger tight;
fitting will be tightened at
a later step.
WHY WHAT
5d
13
12 85-in. cylinder pod
ENP-735 REV C 6/7/2020 (Printed and downloaded copies are uncontrolled) 28 of 75
14
Always use a
backing wrench on the
main fitting while using a
wrench to install another
fitting.
5. Install tube adapter
fitting (17), p/n
10200238 on VTI PRD
(16b), p/n 10300513.
Torque fitting (17)
to 26 ft-lbs
(35.25Nm)
6. Install straight fitting
(18), p/n 10200563, on
VTI PRD (16a), p/n
10300513.
7. Install straight fitting
(18), p/n 10200563, on
VTI PRD (16a), p/n
10300513.
Torque fittings (18)
to 18.5 ft-lbs
(25Nm).
8. Install tube fitting (14),
p/n 10200065, on VTI
PRD (16a), p/n
10300513.
Torque fitting (14)
to 45 ft-lbs (61Nm).
WHY WHAT
16a
14 17
18 16b 18
85-in. cylinder pod
ENP-735 REV C 6/7/2020 (Printed and downloaded copies are uncontrolled) 29 of 75
15 1. Install VTI PRD (16a)
assembly inlet fitting (a)
on PRD supply tube
(13) at tee fitting (12).
2. Install VTI PRD outlet
fitting (16b) on straight
fitting (b) on other end of
PRD supply tube (13).
Tighten fittings finger
tight; fittings will be
torqued at a later step.
PRD ports (c) must
be oriented 90°
down from the flow of
system tubing as shown.
WHY WHAT
a b
16a 16b
13
12
85-in. cylinder pod
c c
ENP-735 REV C 6/7/2020 (Printed and downloaded copies are uncontrolled) 30 of 75
16 1. Install PRD vent tube
(27), p/n 25519027, on
PRD (16a) fitting (a).
Tighten fittings finger
tight; fittings will be
torqued at a later step.
2. Use dual tube clamp, (8)
and plate (6), to secure
PRD supply tube (5d) to
PRD vent tube (27).
3. Slip P-clip (7) on PRD
vent tube (27).
4. Attach P-clip (7) to Pclip
bracket (b) using
existing fasteners (not
visible).
Tighten fasteners finger
tight; fasteners will be
torqued at a later step.
WHY WHAT
a
6
9
8
5d 16a
27
b
7 27
85-in. cylinder pod
ENP-735 REV C 6/7/2020 (Printed and downloaded copies are uncontrolled) 31 of 75
17
a
Use two wrenches to
tighten 1/2-in.
Swagelok® nut fittings at
four locations (circled) in
the following sequence:
1. (a)
2. (b)
3. (c)
4. (d)
Tighten Swagelok® nut
fittings per Appendix B
WI.0441.
WHY WHAT
System specification.
17
b
A. Use two
wrenches to tighten
SAE / JIC nut fittings at
two locations (circled) in
the following sequence:
1. (e)
2. (f)
Tighten SAE / JIC nut
fittings to 45 ft-lbs
(61Nm).
B. Verify vent ports
of VTI PRDs (16a)
and (16b) are
pointed down (arrows).
WHY WHAT
System specification.
85-in. cylinder pod
a
b
d
c
85-in. cylinder pod
e f
16a 16b
ENP-735 REV C 6/7/2020 (Printed and downloaded copies are uncontrolled) 32 of 75
18 1. Install tube clamp
bracket (23), p/n
25519123, on existing
double tube clamp (7)
using the double tube
clamp fasteners (not
shown).
2. Install P-clip (8), p/n
10702147 on PRD vent
tube (37), p/n 25519037.
3. Install P-clip (8) on tube
clamp bracket (23) using
one hex cap screw, p/n
10760200-0100, one flat
washer, p/n 10761000,
and one flange top nut,
p/n 10761300.
Tighten fasteners finger
tight; fasteners will be
tightened at a later step.
WHY WHAT
PRD vent tubes may need
to be adjusted for
clearance.
8
VIEW A
VIEW A
23
23
7
7
37
37
37
85-in. cylinder pod
ENP-735 REV C 6/7/2020 (Printed and downloaded copies are uncontrolled) 33 of 75
19 Tighten fasteners at
clamp and clip
locations (circled) using
the following sequence:
1. (a)
2. (b)
3. (c)
4. (d)
5. (e)
6. (f)
Tighten fasteners to 8 ftlbs
(11Nm).
WHY WHAT
System specification.
20 1. Verify clearance
between PRD vent
tubes (a) and live high
pressure PRD supply
tubes (b) is 3/8-in.
minimum.
2. Verify clearance
between all system
plumbing and cylinders (c)
is 3/8-in. minimum.
If required: Adjust
clamps as necessary and
repeat Step 20.
WHY WHAT
Prevent fuel line damage.
85-in. cylinder pod
d
e f c b a
b
b
a
c
a PLUG END
A
VALVE END
A
85-in. cylinder pod
ENP-735 REV C 6/7/2020 (Printed and downloaded copies are uncontrolled) 34 of 75
21 Apply two Decal,
System, Danger Live
High Pressure PRD Line (a),
p/n 10602157, to PRD
supply tubes as indicated.
WHY WHAT
Operator and first
responder safety.
22 Apply four Decal,
PRD Vent Line,
Caution (b), p/n 10602442,
to midpoint of PRD vent
tubes as indicated.
WHY WHAT
Operator and first
responder safety.
a
a
a
85-in. cylinder pod
b
b
b
b
b
85-in. cylinder pod
ENP-735 REV C 6/7/2020 (Printed and downloaded copies are uncontrolled) 35 of 75
5.4.2. Kit, Retrofit, Gillig, 120″ tanks PRD Retrofit, p/n 25519031, installation instructions
Always perform installation steps in the order specified.
1 Use a 5/16-in. drill
bit to drill one
mounting hole at the
midpoint (DETAIL A) of
each of the 120-in. PRD
brackets (9).
While drilling, carefully
place a section of a
wood 2×4 behind the
hole location to prevent
cylinder damage.
WHY WHAT
Additional mounting holes
are required to secure
clamps to support PRD
vent system.
9
NOTE 1: All dimensions provided in inches.
NOTE 2: Not to scale.
120-in. cylinder pod
ENP-735 REV C 6/7/2020 (Printed and downloaded copies are uncontrolled) 36 of 75
2 1. Install ferrules (not
visible) and nut (a) from
tee fitting (12), p/n
10200208, on PRD vent
tube (13), p/n 25519416.
2. Install ferrules (not
visible) and nut (b) from
tube fitting (14), p/n
10200065, on straight
end of PRD vent tube
(13).
3. Install ferrules (not
visible) and nut (c) from
tee fitting (12), p/n
10200208, on tube
adapter fitting, (17), p/n
10200238.
Refer to Appendix A:
WI.0197 Manual Swaging
of Swagelok Fittings.
4. Install tee fitting (12),
p/n 10200208, on PRD
vent tube, (13), p/n
25519416.
Tighten fitting finger
tight; fittings will be
tightened at a later step.
WHY WHAT
a
13
14
12
b
17
c
12 13
14
120-in. cylinder pod
ENP-735 REV C 6/7/2020 (Printed and downloaded copies are uncontrolled) 37 of 75
3 1. Install two tube clamp
kits (15), p/n 10701508,
from retrofit kit on PRD
tube, (13), p/n
25519417.
2. Insert one 1.5-in. hex
cap screw (a), p/n
10760200-0150, and
one 2.5-in. hex cap
screw (b), p/n
10760200-0120, into
each tube clamp kit (15),
as shown in INSET A.
3. Install one flat washer,
p/n 10761000, and one
flange top nut, p/n
10763000 (not shown)
on each hex cap screw
inserted in previous sub
step.
4. Secure PRD vent tube
(13) to PRD bracket (9)
at holes (circled).
To ease component
installation, do not
tighten fasteners
completely; fasteners
will be tightened at a
later step.
WHY WHAT
Support PRD vent lines.
15
13
9
120-in. cylinder pod
ENP-735 REV C 6/7/2020 (Printed and downloaded copies are uncontrolled) 38 of 75
4 Install PRD vent supply
tube (5d) on tee fitting (12)
nut fitting (a).
Tighten fittings finger
tight; fittings will be
tightened at a later step.
WHY WHAT
12
5d
120-in. cylinder pod
a
ENP-735 REV C 6/7/2020 (Printed and downloaded copies are uncontrolled) 39 of 75
5
Always use a
backing wrench on the
main fitting while using a
wrench to install another
fitting.
1. Install tube adapter
fitting (17), p/n
10200238 on VTI PRD
(16b), p/n 10300513.
Torque fitting (17)
to 26 ft-lbs
(35.25Nm)
2. Install straight fitting
(18), p/n 10200563, on
VTI PRD (16a), p/n
10300513.
3. Install straight fitting
(18), p/n 10200563, on
VTI PRD (16a), p/n
10300513.
Torque fittings (18)
to 18.5 ft-lbs
(25Nm).
4. Install tube fitting (14),
p/n 10200065, on VTI
PRD (16a), p/n
10300513.
Torque fitting (14)
to 45 ft-lbs (61Nm).
WHY WHAT
16a
14 17
18 18
120-in. cylinder pod
16b
ENP-735 REV C 6/7/2020 (Printed and downloaded copies are uncontrolled) 40 of 75
6 1. Install VTI PRD (16a)
assembly inlet fitting (a)
on PRD supply tube
(13) at tee fitting (12).
2. Install VTI PRD (16b)
outlet fitting (b) on
straight end of PRD
supply tube (13).
Tighten fittings finger
tight; fittings will be
torqued at a later step.
WHY WHAT
a 13 b
9
12 16a
16b
120-in. cylinder pod
ENP-735 REV C 6/7/2020 (Printed and downloaded copies are uncontrolled) 41 of 75
7 1. Install PRD vent tube
(28), p/n 25519028, on
tee fitting (12).
Tighten fittings finger
tight; fittings will be
tightened at a later step.
2. Install two Tube Clamp
Kits, 1/2-in., Double
Mounting Hole (7), p/n
10701508, from retrofit
kit on PRD vent tube
(28), and PRD supply
tube (5c).
3. Use dual tube clamp (7)
fasteners (not visible)
from to secure clamps to
PRD bracket (9).
Tighten fasteners finger
tight; fasteners will be
tightened at a later step.
8 1. Slip P-clip (8) removed
earlier on PRD vent tube
(28), p/n 25519028.
2. Secure P-clip (8) to P-clip
bracket (b) using existing
hardware.
Tighten fasteners finger
tight; fasteners will be
tightened at a later step.
WHAT
WHAT
WHY
WHY
12
5c
28 7
9
120-in. cylinder pod
12
5c
28 7
9
120-in. cylinder pod
ENP-735 REV C 6/7/2020 (Printed and downloaded copies are uncontrolled) 42 of 75
9 1. Install nut fitting of PRD
vent tube (37) on VTI
PRD (16a) outlet fitting
(a).
Tighten fitting finger
tight; fitting will be
tightened at a later step.
2. Install tube clamp kit
(15), p/n 10701508, on
PRD vent tube (37).
3. Use tube clamp kit (15)
fasteners (not visible)
from to secure clamp to
PRD bracket (9) at
existing hole using
clamp kit fasteners as
shown in INSET A.
Tighten fasteners finger
tight; fasteners will be
tightened at a later step.
WHY WHAT
15 9 16a 37
120-in. cylinder pod
a
ENP-735 REV C 6/7/2020 (Printed and downloaded copies are uncontrolled) 43 of 75
10 1. Use two wrenches to
tighten Swagelok® nut
fittings in the following
sequence:
1. (a)
2. (b)
3. (c)
Tighten Swagelok®
fittings per Appendix
B WI.0441.
2. Use two wrenches to
tighten SAE / JIC fitting
nuts in the following
sequence:
1. (d)
2. (e)
Torque SAE / JIC
fittings to 45 ft-lbs
(61Nm).
3. Verify vent ports (f) of
VTI PRDs (16a) and
(16b) are pointed down
(arrows).
WHY WHAT
System specification.
a
b
d e
120-in. cylinder pod
16b 16a
f
f
c
ENP-735 REV C 6/7/2020 (Printed and downloaded copies are uncontrolled) 44 of 75
11 1. Install tube clamp
bracket (23), p/n
25519123, to existing
double tube clamp (7).
2. Slip P-clip (8), p/n
10702147, on PRD vent
tube (37), p/n
25519037.
3. Install P-clip (8) on tube
clamp bracket (23), p/n
25519123, using one
hex cap screw, p/n
10760200-0100, one flat
washer, p/n 10761000,
and one flange top nut,
p/n 10761300.
Tighten fasteners finger
tight; fasteners will be
tightened at a later step.
WHY WHAT
System specification.
8
VIEW A
VIEW A
23
23
7
37 7
37
120-in. cylinder pod
37
ENP-735 REV C 6/7/2020 (Printed and downloaded copies are uncontrolled) 45 of 75
12 Tighten clamp
fasteners at all
clamp locations (circled)
using the following
sequence:
1. (a)
2. (b)
3. (c)
4. (d)
5. (e)
6. (f)
7. (g)
Tighten fasteners to 8 ftlbs
(11Nm).
WHY WHAT
System specification.
Proper tightening
sequence is crucial to
fuel system integrity.
120-in. cylinder pod
f
a b c
g
d e
ENP-735 REV C 6/7/2020 (Printed and downloaded copies are uncontrolled) 46 of 75
13 1. Verify clearance
between PRD vent
tubes (a) and live high
pressure PRD vent tubes
(b) is 3/8-in. minimum.
2. Verify clearance
between all system
plumbing and cylinders (c)
is 3/8-in. minimum.
If required: Adjust
clamps as necessary and
repeat Step 11.
WHY WHAT
Prevent fuel line damage.
b
a b
c
b
b
PLUG END
A
VALVE END
A
120-in. cylinder pod
ENP-735 REV C 6/7/2020 (Printed and downloaded copies are uncontrolled) 47 of 75
14 1. Install ferrules (not
visible) and nut (a) from
tee fitting (12), p/n
10200208, on PRD vent
tube (13), p/n 25519416.
2. Install ferrules (not
visible) and nut (b) from
tube fitting (14), p/n
10200065, on straight
end of PRD vent tube
(13).
3. Install ferrules (not
visible) and nut (c) from
tee fitting (12), p/n
10200208, on tube
adapter fitting, (17), p/n
10200238.
Refer to Appendix A:
WI.0197 Manual Swaging
of Swagelok Fittings.
4. Install tee fitting (12), p/n
10200208, on PRD vent
tube, (13), p/n
25519416.
Tighten fitting finger
tight; fitting will be
tightened at a later step.
WHY WHAT
b
13
12
14
a
12
17
c
120-in. cylinder pod
ENP-735 REV C 6/7/2020 (Printed and downloaded copies are uncontrolled) 48 of 75
15 1. Install two tube clamp
kits (15), p/n 10701508,
from retrofit kit on PRD
tube, (13), p/n
25519417.
2. Insert one 1.5-in. hex
cap screw (a), p/n
10760200-0150, and
one 2.5-in. hex cap
screw (b), p/n
10760200-0120, into
each tube clamp kit
(15), as shown in INSET
A.
3. Install one flat washer,
p/n 10761000, and one
flange top nut, p/n
10763000 (not shown)
on each hex cap screw
inserted in previous sub
step.
4. Secure PRD vent tube
(13) to PRD bracket (9)
at holes (circled).
To ease component
installation, do not
tighten fasteners
completely; fasteners
will be torqued at a later
step.
WHY WHAT
Support PRD vent lines.
15
13
9
120-in. cylinder pod
ENP-735 REV C 6/7/2020 (Printed and downloaded copies are uncontrolled) 49 of 75
16 Install PRD vent supply
tube (5d) on tee fitting (12)
at nut fitting (a).
Tighten fitting (a) finger
tight; fitting will be
tightened at a later step.
WHY WHAT
12
5d
120-in. cylinder pod
a
ENP-735 REV C 6/7/2020 (Printed and downloaded copies are uncontrolled) 50 of 75
17
Always use a
backing wrench on the
main fitting while using a
wrench to install another
fitting.
1. Install tube adapter
fitting (17), p/n
10200238 on VTI PRD
(16b), p/n 10300513.
Torque fitting (17)
to 26 ft-lbs
(35.25Nm)
2. Install straight fitting
(18), p/n 10200563, on
VTI PRD (16a), p/n
10300513.
3. Install straight fitting
(18), p/n 10200563, on
VTI PRD (16a), p/n
10300513.
Torque fittings (18)
to 18.5 ft-lbs
(25Nm).
4. Install tube fitting (14),
p/n 10200065, on VTI
PRD (16a), p/n
10300513.
Torque fitting (14)
to 45 ft-lbs (61Nm).
WHY WHAT
16a
14 17
18 16b 18
120-in. cylinder pod
ENP-735 REV C 6/7/2020 (Printed and downloaded copies are uncontrolled) 51 of 75
18 1. Install VTI PRD (16a)
assembly inlet fitting (a)
on PRD supply tube
(13) at tee fitting (12).
2. Install VTI PRD (16b)
outlet fitting (b) on
straight end of PRD
supply tube (13) nut
fitting.
Tighten fittings finger
tight; fittings will be
torqued at a later step.
WHY WHAT
b 13 12 a
16b 16a
120-in. cylinder pod
ENP-735 REV C 6/7/2020 (Printed and downloaded copies are uncontrolled) 52 of 75
19 1. Install PRD vent tube
(29), p/n 25519027, on
VTI PRD (16b) fitting
(a).
Tighten nut fitting finger
tight; fittings will be
tightened at a later step.
2. Slip two dual tube
clamps (8) on PRD vent
tube (29), and on PRD
supply tube (5d).
3. Use dual tube clamp (8)
fasteners (not visible) to
secure two clamps (8)
and two plates (6), to
PRD bracket (9) at hole
(circled).
4. Slide P-clip (7) on PRD
vent tube (29) and use
existing fastener to
secure P-clip (7) to Pclip
bracket (b).
Tighten fasteners finger
tight; fasteners will be
torqued at a later step.
WHY WHAT
5d
16b a 8 6 29
7
b
120-in. cylinder pod
ENP-735 REV C 6/7/2020 (Printed and downloaded copies are uncontrolled) 53 of 75
20 1. Install nut fitting (b) of
PRD vent tube (38) on
VTI PRD (16a) outlet
fitting (a).
Tighten fitting finger
tight; fitting will be
tightened at a later step.
2. Install tube clamp kit
(15), p/n 10701508, on
PRD vent tube (38).
3. Use tube clamp kit (15)
fasteners (not visible)
from to secure clamp to
PRD bracket (9).
Tighten fasteners finger
tight; fasteners will be
tightened at a later step.
WHY WHAT
15 16a
9
38
120-in. cylinder pod
b a
ENP-735 REV C 6/7/2020 (Printed and downloaded copies are uncontrolled) 54 of 75
21 A. Use two
wrenches to tighten
1/2-in. Swagelok® nut
fittings at four locations in
the following sequence:
1. (a)
2. (b)
3. (c)
4. (d)
Tighten 1/2-in.
Swagelok® nut fittings
per Appendix B WI.0441.
B. Verify vent ports (f)
of VTI PRDs (16a)
and (16b) are pointing
down (arrows).
WHY WHAT
System specification.
120-in. cylinder pod
16a b a
d
16b
f
f
c
ENP-735 REV C 6/7/2020 (Printed and downloaded copies are uncontrolled) 55 of 75
22 Use two wrenches to
tighten SAE / JIC
fittings at two locations
(circled) in the following
sequence:
1. (a)
2. (b)
Tighten SAE / JIC fittings
to 45 ft-lbs (61Nm).
WHY WHAT
System specification.
120-in. cylinder pod
a b
ENP-735 REV C 6/7/2020 (Printed and downloaded copies are uncontrolled) 56 of 75
23 1. Install tube clamp
bracket (23), p/n
25519123, on existing
double tube clamp (7).
2. Slip P-clip (8), p/n
10702147, on PRD vent
tube (38), p/n 25519038.
3. Install P-clip (8) on tube
clamp bracket (23), p/n
25519123 using one
hex cap screw, p/n
10760200-0100, one flat
washer, p/n 10761000,
and one flange top nut,
p/n 10761300.
Tighten fasteners finger
tight; fasteners will be
tightened at a later step.
WHY WHAT
System specification.
8
23
38
7
120-in. cylinder pod
ENP-735 REV C 6/7/2020 (Printed and downloaded copies are uncontrolled) 57 of 75
24 Tighten clamp
fasteners at all clip
and clamp locations
(circled) using the following
sequence:
1. (a)
2. (b)
3. (c)
4. (d)
5. (e)
6. (f)
7. (g)
Tighten fasteners to 8 ftlbs
(11Nm).
WHY WHAT
System specification.
Proper tightening
sequence is crucial to
fuel system integrity.
120-in. cylinder pod
f
c b a
g
e
d
ENP-735 REV C 6/7/2020 (Printed and downloaded copies are uncontrolled) 58 of 75
25 1. Verify clearance
between PRD vent
tubes (a) and live high
pressure PRD supply
tubes (b) is 3/8-in.
minimum.
2. Verify clearance
between all system
plumbing and cylinders (c)
is 3/8-in. minimum.
If required: Adjust
clamps as necessary and
repeat Step 22.
WHY WHAT
Prevent fuel line and
cylinder damage.
b
a
c
b
b
PLUG END
A
VALVE END
A
c
120-in. cylinder pod
ENP-735 REV C 6/7/2020 (Printed and downloaded copies are uncontrolled) 59 of 75
26 Apply quantity four
Decal, System,
Danger Live High Pressure
PRD Line (a), p/n
10602157, to PRD supply
tubes as indicated.
WHY WHAT
Operator and first
responder safety.
27 Apply quantity four
Decal, PRD Vent Line,
Caution (b), p/n 10602442,
to midpoint of PRD vent
tubes as indicated.
WHY WHAT
Operator and first
responder safety.
a
a a
120-in. cylinder pod
b
b
b
b
b
120-in. cylinder pod
ENP-735 REV C 6/7/2020 (Printed and downloaded copies are uncontrolled) 60 of 75
5.4.3. Check PRD vent tube outlet clearance
1 1. Gently close one
fuel system roof
pod door.
2. Visually verify proper
clearance between plug
end PRD vent tube cap
(f) and door opening
(circled).
3. Visually verify proper
clearance between
valve end PRD vent
tube caps (f) and door
opening (circled).
PRD vent tubes cannot
protrude above the top of
the pod door.
If PRD vent tube caps
protrude above the pod
door opening, fuel system
plumbing must be adjusted
to achieve proper
clearance.
2 Repeat Step 1 for each roof
pod door.
WHAT
WHAT
WHY
Verify proper PRD vent
tube position.
WHY
Verify proper PRD vent tube
position.
12
5a
f f 15
9
f
f
ENP-735 REV C 6/7/2020 (Printed and downloaded copies are uncontrolled) 61 of 75
5.5. System Leak Check Procedure
1 1. Turn 1/4-turn manual shut
off valve (3) on the FMM (2)
to the OPEN position.
2. Select the appropriate CNG
fuel nozzle and/or adaptor
for the FMM (2) fuel fill
receptacle (not visible).
3. Remove fuel fill receptacle
dust cap (f).
4. Begin fueling the vehicle
with CNG using a regulated
fuel supply.
Open nozzle valve slowly
and regulate gas delivery to
prevent connector from icing
and reducing or blocking
fuel flow.
Follow all local and facility
fueling regulations and
procedures.
WHY WHAT
Test fuel system integrity.
2
f
3
ENP-735 REV C 6/7/2020 (Printed and downloaded copies are uncontrolled) 62 of 75
2 Monitor FMM (2) high
pressure gauge (b) to
verify when system
pressure reaches 500
psi to 510 psi (3.45MPa
to 3.52MPa) and stop
pressurization.
.⚠
1. If a hissing sound is
heard coming from
fuel system fittings
during filling, stop
the fill immediately.
2. Try to isolate the
sound and spray
Swagelok Snoop®
on the suspected
location to check for
bubble formation.
3
Leak test all fuel and
PRD tubes and fitting
connections using Swagelok
Snoop® leak detection solution
or equivalent.
WHAT
WHAT
WHY
Subjects fuel system to
partial operating
pressure.
WHY
Approved leak detection
solution for visual inspection
of system leaks.
2 b
ENP-735 REV C 6/7/2020 (Printed and downloaded copies are uncontrolled) 63 of 75
4 1. Begin at one end the
of the fuel system
and work
methodically to spray
all fuel line fittings
with Swagelok
Snoop® or equivalent.
2. Allow at least 10
minutes to elapse
before checking the
integrity of fitting
connections.
5 If a leak is audible or icing,
condensation, foam, or
bubbles appear at a fitting
connection the fitting
connection must be
inspected.
Fuel system must be
defueled prior to
investigating any leak.
Refer to OEM procedure to
defuel system.
WHAT
WHAT
WHY
WHY
6 Re-tighten leaking
fitting(s) discovered
during Step 5.
1. For JIC fittings,
refer to p/n specific
tightening
instructions.
2. For compression
fittings, tighten
fitting according to
Appendix B.
7 Repeat Steps 1 and 2 to
repressurize the system.
WHAT
WHAT
WHY
WHY
ENP-735 REV C 6/7/2020 (Printed and downloaded copies are uncontrolled) 64 of 75
8 Spray leaking fitting
again with Swagelok
Snoop® or equivalent
and allow at least 10
minutes to elapse before
checking for bubble
formation.
9
If leaking fitting is fixed,
proceed to test any remaining
fitting connections.
WHAT
WHAT
WHY
WHY
10
If leak is not fixed, the
fuel system must be
defueled to replace the
fitting.
Perform OEM defuel
procedure.
11 Inspect tubing, fittings,
ferrules, and nuts at the site of
the leak for perforations,
cracks, assembly defects, or
other damage.
Any damaged components
must be replaced.
WHAT
WHAT
WHY
WHY
12 Replace any related
components at the fitting
junction as required.
Follow fitting
installation directions
in Appendix 2.
13 Repressurize fuel system by
repeating Step 1 and Step 2.
WHAT
WHAT
WHY
WHY
ENP-735 REV C 6/7/2020 (Printed and downloaded copies are uncontrolled) 65 of 75
14
Spray new fitting
junction with Swagelok
Snoop® or equivalent to
retest for leaks.
15 Turn FMM 1/4-turn manual
shut off valve (3)
counterclockwise to the
OPEN position.
WHAT
WHAT
WHY
WHY
Allow fuel into system.
16
Repeat pressure
test procedure stopping
the fill when fuel system
pressure reaches 2000
psi to 2100 psi
(13.79MPa to
14.48MPa).
17
Repeat pressure test
procedure stopping the fill
when fuel system pressure
reaches 3600 psi to 3700 psi
(24.8MPa to 25.5MPa) and
repeat leak checking all
connections until the entire
fuel system is confirmed leak
free.
WHAT
WHAT
WHY
Subjects fuel system to
partial operating
pressure.
WHY
Subjects fuel system to full
operating pressure.
18
If fuel system is leak
free or if defueling is
required, close flow
valve on CNG dispense
nozzle (not shown) and
carefully disconnect fill
nozzle (not shown) from
FMM fuel fill receptacle.
19 Replace dust cap (f) on FMM
(2) fuel fill receptacle (not
visible).
WHAT
WHAT
WHY
WHY
Vehicle will not start if dust
cap is not in place.
2
f
ENP-735 REV C 6/7/2020 (Printed and downloaded copies are uncontrolled) 66 of 75
20 If not open, turn FMM
(2) 1/4-turn manual shut
off valve (3)
counterclockwise to the
OPEN position.
21
Use shop towels to clean
Swagelok Snoop® or
equivalent from the fuel
system.
WHAT
WHY
Allow gas to flow
throughout fuel system.
WHY
Customer satisfaction.
22
When the pressure test
is completed
successfully, use form
FT.0320 (c) to record
the result and the date
on which the fuel system
passed the 3600 psi
test.
23 Apply Torque Seal (a) to all
fitting junctions (b).
WHAT
WHY
Verify safe and proper
fuel system pressure
specification.
System quality specification.
3
2
c
b
a
ENP-735 REV C 6/7/2020 (Printed and downloaded copies are uncontrolled) 67 of 75
5.6. Reporting and Return Procedure
1 1. Use form FT.0320
(c) to record the
serial number (a) and
the location of each VTI
replacement PRD (16),
p/n 10300513,within the
fuel system.
2. Inspect fuel system
repairs per the quality
assurance criteria
specified in FT.0320.
Use a flashlight to aid
serial number identification
in low light.
3. Use a camera or
camera phone to take a
photo of completed form
FT.0320 (c).
4. Submit photo of
completed form FT.0320
(c) to the email address
indicated on the form to
receive a Return
Material Authorization
(RMA) shipping label.
WHY WHAT
Required for retrofit kit
component and repair
tracking and, if applicable,
installer reimbursement.
c
16
a
ENP-735 REV C 6/7/2020 (Printed and downloaded copies are uncontrolled) 68 of 75
2 Repeat Section 5.
Corrective Action /
Procedure for all vehicles
subject to the Emer™ PRD
recall on hand until all
repairs are complete.
3
1. Pack all removed PRDs
(still bagged by VIN), in one
box. If the quantity of PRDs
is too large for a single box,
use additional boxes but
ship them all using the
same RMA.
If possible: reuse the box in
which the replacement
PRDs were shipped.
2. Apply RMA label obtained
from Agility® to the box.
3. Use a permanent marker to
write RMA number on
exterior of each shipping
box.
WHAT
WHAT
WHY
WHY
Required for repair return
tracking and, if applicable,
installer reimbursement.
ENP-735 REV C 6/7/2020 (Printed and downloaded copies are uncontrolled) 69 of 75
Appendix A. WI.0197 Manual Swaging of Swagelok Fittings
ENP-735 REV C 6/7/2020 (Printed and downloaded copies are uncontrolled) 70 of 75
ENP-735 REV C 6/7/2020 (Printed and downloaded copies are uncontrolled) 71 of 75
ENP-735 REV C 6/7/2020 (Printed and downloaded copies are uncontrolled) 72 of 75
ENP-735 REV C 6/7/2020 (Printed and downloaded copies are uncontrolled) 73 of 75
Appendix B. WI.0441 Tightening of tube fittings
ENP-735 REV C 6/7/2020 (Printed and downloaded copies are uncontrolled) 74 of 75
ENP-735 REV C 6/7/2020 (Printed and downloaded copies are uncontrolled) 75 of 75
6. Warranty Information
This procedure is covered under warranty. Standard repair time (SRT) is 6.0 hours. Please
refer to Warranty Manual, ENP-067, for warranty reimbursement procedures.
For parts and support, contact Agility Fuel Solutions Customer Care:
+1 949 267 7745
+1 855 500 2445 toll free
[email protected]
Proprietary Statement
The information provided within this document is proprietary and confidential. All prior
versions, including updates and revisions forwarded separately, are proprietary. The
information provided by Agility® to its customers and clients is solely for the use of those
customers and clients. No portion of this publication may be reproduced or distributed without
express written consent of Agility®. Agility® reserves the right to utilize the intellectual property
contained within this publication as content for any other publication produced by Agility®.
Trademark Notice
Agility® is registered trademark of Agility Fuel Solutions LLC. Trademarks of other
manufacturers are the property of their respective companies.
Agility Fuel Solutions | 3335 Susan Street Suite 100 | Costa Mesa, CA 92626 USA
www.agilityfuelsolutions.com
Revision Description Author Approved By Date
— Initial Release C. Grasso CCG Team 05/04/2020
A
ADDED: References to
FT.0320 tracking and quality
inspection document.
REVISED: retrofit kit contents.
DELETED: non-required p/ns
from corresponding install
steps.
C. Grasso CCG Team 05/07/2020
B
REVISED: Section 5.3 Step 1
disassembly sequence
C. Grasso CCG Team 05/28/2020
C
REVISED: Fitting and clamp
tightening sequences.
C.Grasso CCG Team 06/07/2020