Ford F-59 CNG HP Fuel Filter Bowl & Bleed Valve Retrofit – MY2019 Ford F-59 CNG Package Vans

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Field Service Bulletin
FSB.0003 Ver 1.0
August 16, 2021
Ford F-59 CNG HP Fuel Filter Bowl & Bleed Valve Retrofit
Affected Vehicles
QTY: 800 MY2019 Ford F-59 CNG package vans
 UPS Job # 20-26 P80 / UPS Job # 20-27 P100 / UPS Job # 20-28 P120
 UPS Package Car Ranges: 170855 – 170984
199419 – 199768
834055 – 834162
834579 – 834790
Introduction
Agility Fuel Solutions LLC, a subsidiary of Hexagon Agility Inc. (Hexagon Agility®), has redesigned the CNG high-pressure (HP) fuel filter bowl to incorporate a bleed valve to facilitate fuel system depressurization.
RECOMMENDED: Install this retrofit kit at the regular HP fuel filter element replacement interval.
Hexagon Agility® has created this informational and instructional document for retrofit kit installation.
Warning Statements Used in this Bulletin
WARNING indicates a hazardous situation which, if not avoided, could result in death or serious injury.
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.
CRITICAL CHARACTERISTIC – Product feature directly affects:
 Safety of vehicle users, people nearby and maintenance personnel, or
 Regulatory compliance.
MANUFACTURING CHARACTERISTIC –
 A product feature solely used to improve manufacturability or maintain process control.
 A process parameter or step that has a significant effect on achieving a Critical Characteristic or Significant Characteristic, or maintaining material identification/ traceability.
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Required Tools and Materials
Item
Purpose
safety glasses
eye protection
7/16-in wrench
tighten bleed valve pressure relief nut
11/16-in wrenches (QTY: 2)
remove and install fuel system fasteners and fittings
11/16-in crowfoot wrench
torque bleed valve
55 mm crowfoot wrench
remove and install HP fuel filter bowl
torque wrench
accurately tighten fuel system fittings, fasteners, and components
11/16-in crowfoot wrench
use with torque wrench to tighten bleed valve
Swagelok® Snoop® leak detection fluid
perform leak test
Torque Seal (any color but yellow)
indicate fittings and fasteners are tightened to specifications
shop rags
clean fuel system components before and after repair
O-ring lubricant
lubricate O-ring for proper seating, seal, and protection
1/4-in allen wrench
remove high-pressure filter drain plug
Supplied Components and Required Parts
Part Number
Description
QTY
69000538
Kit, filter, bowl, CNG, HP fuel, bleed valve
1
cap, pressure relief nut
HP fuel filter bowl
O-ring, fuel filter bowl
decal, fuel filter
bleed valve assembly
cap, pressure relief port
bleed valve
Kit, service, filter element (Hexagon Agility® p/n 69000481) is a regular maintenance item required for this installation and is not included in the retrofit kit.
If any parts are missing or unusable, contact Hexagon Agility® Customer Care and Technical Services (CCTS) for replacement.
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Warranty Information
This procedure is covered under the provisions of the fuel system warranty.
1. Close driver side (DS) cylinder manual valve (1). FIGURE 2–1
FIGURE 2–1. (1) DS manual cylinder valve, (2) PS manual cylinder valve, (3) 1/4-turn manual shutoff valve
2. Close passenger side manual valve (2). FIGURE 2–1
3. Close 1/4-turn manual shutoff valve (3). FIGURE 2–1
4. Start engine and idle until engine stalls.
5. Attempt to start engine again.
a. If engine starts, allow engine to idle until it stalls.
b. Repeat Step 5 until engine fails to start.
1. Vehicle Preparation
2. Depressurization Procedure
3
1
2
FRONT
Set emergency brake and place wheel chocks in front of and behind tires.
Wear approved personal protective equipment (PPE) including safety glasses.
Fuel lines must be depressurized before servicing fuel system components.
Vehicle will be immobile after depressurization; plan accordingly.
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6. Purge remaining fuel pressure by using a 1/4-in Allen wrench to slowly loosen (4) high-pressure (HP) fuel filter (5) drain plug 1/2-turn to 3/4-turn and retighten drain plug. Repeat loosen-tighten sequence until sound of escaping fuel is heard. FIGURE 2–2
FIGURE 2–2. (4) HP fuel filter assembly, (5) drain plug
7. Remove (5) HP fuel filter drain plug and allow any remaining fuel pressure to escape from (4) HP fuel filter assembly before proceeding to retrofit kit installation. FIGURE 2–3
FIGURE 2–3. (4) HP fuel filter assembly, (5) drain plug (removed)
5
4
FRONT
DO NOT remove (5) HP fuel filter drain plug until fuel pressure has been released following multiple loosen and tighten sequences.
HP fuel filter bowl may contain fluid. Collect fluid in a container and dispose of fluid in compliance with authority having jurisdiction (AHJ) or organizational guidelines.
5
4
FRONT
Once removed, drain plug has no sealing ability and cannot be safely reused.
Recycle or discard (5) drain plug in compliance with AHJ or organizational guidelines.
Step 6 must be performed slowly and incrementally to abrade the HP fuel filter drain plug O-ring to allow a safe and gradual release of fuel pressure. Do not completely remove drain plug at this time; retighten and loosen plug as directed until the sound of escaping fuel is audible.
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1. If present: remove existing (d) decal from (3) HP fuel filter head. FIGURE 3–1
FIGURE 3–1. (2) high-pressure (HP) fuel filter assembly, (3) HP fuel filter head, (d) decal
2. Clean (2) HP fuel filter assembly thoroughly and use a 55 mm wrench to remove (1) filter bowl from (3) HP fuel filter head. FIGURE 3–2
FIGURE 3–2. (2) HP fuel filter assembly, (3) HP fuel filter head, (1) filter bowl
3. Installation Procedure
3
d
FRONT
2
1
3
FRONT
2
Recycle or discard (1) old HP fuel filter bowl in compliance with AHJ or organizational guidelines.
NOTE: (1) filter bowl will not be reused; recycle or discard.
NEVER put a wrench on a fuel system fitting without first confirming the system has been depressurized.
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3. Remove (4) filter element from (3) HP fuel filter head. FIGURE 3–3
FIGURE 3–3. (3) HP fuel filter head, (4) filter element
4. Inspect (s) filter element stem inside (3) HP fuel filter head. FIGURE 3–4
FIGURE 3–4. (3) HP fuel filter head, (s) filter element stem, (t) thread location
5. Clean and inspect (3) HP fuel filter head threads (not visible) at location (t) for debris, cross-threading, burrs, etc. If HP fuel filter head threads are damaged, obtain replacement HP fuel filter assembly from Hexagon Agility® CCTS.
4
3
FRONT
Discard used filter element in compliance with AHJ or organizational guidelines.
(s) filter element stem is an integral part of the (3) HP fuel filter head. If (s) stem is damaged or missing, obtain new HP fuel filter assembly, from Hexagon Agility® CCTS. FIGURE 3–4
s
3
FRONT
t
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6. Install retrofit kit (o) O-ring, in (5) retrofit kit HP fuel filter bowl (g) groove. FIGURE 3–5
FIGURE 3–5. (5) HP fuel filter bowl, (o) O-ring, (g) groove
7. Install new (4) filter element (Hexagon Agility® p/n 69000481—kit available separately) in (3) HP fuel filter head. FIGURE 3–6
FIGURE 3–6. (3) HP fuel filter head, (4) filter element
8. Use a 55 mm wrench to install (5) retrofit HP fuel filter bowl on (3) HP fuel filter head. FIGURE 3–7
FIGURE 3–7. (5) retrofit HP fuel filter bowl, (3) HP fuel filter head
5
o
g
4
3
FRONT
Torque (5) filter bowl to 60 ft-lbs (81.3 Nm).
3
5
FRONT
Apply a light coat of O-ring lube to (o) O-ring before installing.
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9. Clean (3) HP fuel filter head and (5) fuel filter bowl for decal installation. FIGURE 3–8
FIGURE 3–8. (3) HP fuel filter head, (5) retrofit HP fuel filter bowl, (8) bleed valve, (6) filter decal, (p) outlet port
10. Install (6) fuel filter decal on (1) HP fuel filter head with flow arrow pointing towards the fuel filter head (p) outlet port. FIGURE 3–8
11. Remove pressure relief port cap and pressure relief nut cap from (8) bleed valve. FIGURE 3–9
FIGURE 3–9. (5) retrofit HP fuel filter bowl, (8) bleed valve, (v) pressure relief port, pressure relief port cap, pressure relief nut cap
12. Verify pressure relief nut is fully closed using a 7/16-in wrench. FIGURE 3–10
FIGURE 3–10. (8) bleed valve, pressure relief nut
5
6
FRONT
3
p
8
7
8
v
pressure relief nut cap
pressure relief port cap
To increase service life, ensure proper valve performance, and prevent leakage, apply only enough torque to pressure relief nut as required to achieve positive shutoff per Swagelok® instructions.
pressure relief nut
FRONT
8
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1. With an assistant, open DS cylinder manual valve while observing HP gauge on fuel fill panel until it reads 500 psi (3.45 MPa) and close the manual cylinder valve. FIGURE 4–1
FIGURE 4–1. Fuel fill panel, (9) HP gauge reading 500 psi, (4) 1/4-turn manual shutoff valve, (5) DS cylinder manual valve
2. Open 1/4-turn manual shutoff valve. FIGURE 4–1
3. Listen for hissing as a sign of a system leak.
4. Apply Swagelok® Snoop® leak detection solution to HP fuel filter bowl-filter head junction, all HP fuel filter fittings and the bowl to bleed valve interface, and pressure relief ports and wait 3 minutes. FIGURE 4–2
FIGURE 4–2. Apply Swagelok® Snoop® to (4) HP fuel filter assembly and (8) bleed valve at locations circled
4. Leak Test Procedure
1
FRONT
4
5
9
4
9
pressure relief port
filter bowl to bleed valve interface
HP fuel filter bowl-filter head junction
HP fuel filter fittings
STOP fuel flow immediately if loud hissing indicative of a fuel leak is audible.
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5. Inspect all HP fuel filter fitting and component junctions for bubbles as an indicator of a leak. FIGURE 4–3
FIGURE 4–3. Swagelok® Snoop®, bubbles forming at a fitting junction
a. If no leaks are found, proceed to next step.
b. If leaks are found, purge fuel from the vehicle using the procedure described above in Section 1, Steps 1 through 5.
c. Use a 7/16-in wrench to slowly loosen the pressure relief nut. FIGURE 4–4
FIGURE 4–4. (8) bleed valve, pressure relief nut
d. Tighten the pressure relief nut to finger tight then use a 7/16-in wrench to apply just enough pressure to stop the flow of fuel. FIGURE 4–4
e. Repair leak(s) before repeating Leak Test Procedure. Refer to ENP-516, Truck and Tractor CNG Fuel System Operation, Maintenance & Inspection Manual, “Leak Repair” section.
Swagelok® Snoop® bottle
bubble formation indicative of a fitting leak
To increase service life, ensure proper valve performance, and prevent leakage, apply only enough torque to pressure relief nut as required to achieve positive shutoff per Swagelok® instructions.
pressure relief nut
FRONT
8
NEVER attempt to tighten fittings while system is pressurized.
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6. With an assistant, open DS cylinder manual valve while observing HP gauge on fuel fill panel until it reads 1800 psi (12.4 MPa) and close the manual cylinder valve. FIGURE 4–5
FIGURE 4–5. Fuel fill panel, (9) HP gauge reading 1800 psi, (4) 1/4-turn manual shutoff valve, (5) DS cylinder manual valve
7. Repeat Steps 4 through 5 until no leaks are present, then proceed to Step 8.
8. With an assistant, open DS cylinder manual valve while observing HP gauge on fuel fill panel until it reads 3600 psi (24.6 MPa) and close the manual cylinder valve. FIGURE 4–6
FIGURE 4–6. Fuel fill panel, (9) HP gauge reading 3600 psi, (4) 1/4-turn manual shutoff valve, (5) DS cylinder manual valve
9. Repeat Steps 4 through 5 until no leaks are present, then proceed to Step 10.
10. When the system passes the 3600 psi (24.6 MPa) leak test, use shop rags to clean all Swagelok® Snoop® from fuel system components.
1
FRONT
4
5
9
If less than 1800 psi of fuel is onboard, refuel system to 1800 psi. Refer to ENP-516, Truck and Tractor CNG Fuel System Operation, Maintenance & Inspection Manual, “CNG System Fueling” section.
1
FRONT
4
5
9
If less than 3600 psi of fuel is onboard, refuel system to 3600 psi. Refer to ENP-516, Truck and Tractor CNG Fuel System Operation, Maintenance & Inspection Manual, “CNG System Fueling” section.
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11. Use a Torque Seal marker (any color but yellow) to mark properly tightened fuel system fittings and the bleed valve pressure relief nut. FIGURE 4–7
FIGURE 4–7. (8) bleed valve, pressure relief nut, fitting junction marked with Torque Seal
12. Install pressure relief port cap, p/n 61090128, and bleed valve cap, p/n 61090129, on (v) pressure relief port and (8) bleed valve pressure relief nut. FIGURE 4–8
FIGURE 4–8. (5) retrofit HP fuel filter bowl, (8) bleed valve, (v) pressure relief port, pressure relief port cap, pressure relief nut cap
13. Road test vehicle using the procedure described below.
1. Verify 1/4-turn manual shutoff valve, DS manual cylinder valve, and PS manual cylinder valve, are open.
2. Remove wheel chocks from front and rear of tires.
3. Start engine and verify proper fuel system operation.
4. Road test the vehicle until it reaches operating temperature.
5. If a system fault appears, contact Hexagon Agility® CCTS.
6. If system is operating properly, release vehicle into service.
7. Update vehicle maintenance and repair records.
pressure relief nut
Torque Seal
7
8
v
Obtain replacements from Hexagon Agility® CCTS if either cap is missing.
pressure relief nut cap
pressure relief port cap
5. Road Test Procedure
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Appendix A. WI.0199 – Removal and Retightening of Tube Fittings
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Hexagon Agility® Customer Care and Technical Services
Fuel system warranty or non-warranty product support may be obtained by calling or emailing Hexagon Agility® Customer Care and Technical Services (CCTS).
Please provide your name, phone number, email address, and complete vehicle information: VIN, year, make, model, mileage, unit number vehicle owner, and current vehicle location. A service advisor will contact you to arrange vehicle repair or ship a part.
+1 877 234 1722
(toll-free, U.S. and Canada)
UPS Direct Access Prompt: 6
Support
support@hexagonagility.com
Parts Orders
parts@hexagonagility.com
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 Hexagon 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 Hexagon Agility®. Hexagon Agility® reserves the right to utilize the intellectual property contained within this publication as content for any other publication produced by Hexagon Agility®.
Trademark Notice
Hexagon® is a registered trademark of Hexagon Technology AS. Agility® is a registered trademark of Agility Fuel Solutions LLC. Trademarks of other manufacturers are the property of their respective companies.
Hexagon Agility® 3335 Susan Street, Suite 100 Costa Mesa, CA 92626 USA www.hexagonagility.com

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