UPS Ford F-59 CNG Project 3 Defueling Procedure – 2019 Ford F-59 CNG Package Vans

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Field Repair Instructions
FRI.0002 Ver 1.0
August 16, 2021
UPS Ford F-59 CNG Project 3 Defueling Procedure
UPS Job # 20-26 P80 / # 20-27 P100 / Job # 20-28 P120
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 established this service procedure for defueling certain UPS Ford F-59 CNG package vans (refer to “Affected Vehicles” section above for details).
FIGURE I–1. LEFT: HP fuel filter bowl (OBSOLETE), drain plug (OBSOLETE)
RIGHT: HP filter bowl (CURRENT SPEC), bleed valve assembly (CURRENT SPEC)
HP filter bowl and bleed valve retrofit must be completed prior to using this procedure. Refer to FSB.0003.
bleed valve assembly; current specification
HP filter fuel bowl, OBSOLETE
HP filter fuel bowl; current specification
HP filter drain plug, OBSOLETE

Before proceeding further, please inspect the HP fuel filter (located on the driver side chassis frame rail) for the presence of a bleed valve in the filter bowl. FIGURE I–1
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Warning and Signal Words 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.
Required Tools and Materials
Item
Purpose
safety glasses
eye protection
5/8-in wrench (QTY:2)
remove and replace defuel kit fitting
5/8-in wrench crowfoot wrench
use with torque wrench to tighten defuel kit fitting
7/16-in wrench
tighten bleed valve pressure relief nut
11/16-in wrench
remove and replace bleed valve
11/16-in crowfoot wrench
use with torque wrench to tighten bleed valve
torque wrench
accurately tighten fuel system fittings and components
defueling service kit, CNG – Hexagon Agility® p/n 69500019
adaptor to defuel hose, ground cable, solenoid purge harness
35-ft defueling hose – Hexagon Agility® p/n 20100021*
remove CNG from fuel system
Swagelok® Snoop® leak detection fluid
perform leak test
Torque Seal (any color but yellow)
indicate fittings are tightened to specifications
shop rags
clean fuel system components before and after repair
O-ring lubricant
lubricate O-rings for proper seating, seal, and protection
*Required if a hose is not present at defuel vent stack.
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Fuel System Schematic
Item
Description
1
fuel fill panel
2
driver side (DS) cylinder
3
passenger side (PS) cylinder
4
1/4-turn manual shutoff valve
5
driver side (DS) cylinder manual valve
6
passenger side (PS) cylinder manual valve
7
HP fuel filter
8
bleed valve
9
HP fuel gauge
FRONT
1
2
3
8
4
7
5
6
9
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Defueling Diagram
Defueling Special Tools
Item
Part Number
Description
A
69500019
Kit, defueling
B
(POA A)
Supply solenoid valve (SSV) jumper cable – NOTE: not used for this procedure
C
(POA A)
Ground cable
D
(POA A)
Defuel adaptor hose
E
20100021
Defueling hose, 35-ft
defuel hose
– electrically conductive, flexible
manual valve
vent stack/pipe
– properly supported,
minimum 10-ft (3 m) above fuel vessel
grounding rod
– minimum 8-ft
(2.44 m) deep
defuel hose nozzle
defuel adaptor hose receptacle
To rest of fuel system
ground cable clips
ground cable
support structure or building wall
bracket
(vehicle)
HP filter
NGV valve
defuel adaptor hose
defuel adaptor hose fitting
defuel hose connector
ground cable clip
C
B
D
E
A
POA = part of assembly/kit; item not available separately
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1. Close driver side (DS) cylinder manual valve (5). FIGURE 2–1
FIGURE 2–1. (5) DS manual cylinder valve, (6) PS manual cylinder valve, (4) 1/4-turn manual shutoff valve
2. Close passenger side manual valve (6). FIGURE 2–1
3. Close 1/4-turn manual shutoff valve (4). 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
Set emergency brake and place wheel chocks under vehicle tires.
Wear approved personal protective equipment (PPE) including safety glasses.
Before servicing fuel system plumbing and components, fuel pressure must be released using a depressurization procedure.
2. Depressurization Procedure
Depressurization and defueling must be performed in well-ventilated area.
4
5
6
FRONT
Vehicle will be immobile after depressurization; plan accordingly.
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6. Remove bleed valve pressure relief port cap and pressure relief nut cap from (8) bleed valve located on (7) HP fuel filter. FIGURE 2–2
FIGURE 2–2. (7) HP fuel filter, (8) bleed valve, pressure relief port cap, pressure relief nut cap
7. Use a 7/16-in wrench to loosen pressure relief nut on the (8) bleed valve. FIGURE 2–3
FIGURE 2–3. (7) HP fuel filter, (8) bleed valve, pressure relief nut, pressure relief port
pressure relief nut cap
pressure relief port cap
7
8
Store caps in a clean, dry plastic bag for reinstallation later.
High pressure fuel and condensation will exit from pressure relief port; wear appropriate PPE and maintain safe distance.
8
7
FRONT
pressure
relief nut
pressure relief port
high pressure fuel escaping
Listen for the flow of escaping fuel to stop to verify pressure has been fully released.
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FIGURE 3–1. (1) fuel fill panel, (9) HP fuel gauge
1. Verify (5) driver side (DS) cylinder manual valve and (6) passenger side (PS) cylinder manual valve are closed. NOTE: Cylinder shields not shown. FIGURE 3–2
FIGURE 3–2. (4) 1/4-turn manual shutoff valve, (5) DS cylinder manual valve, (6) PS cylinder manual valve
2. Verify (4) 1/4-turn manual shutoff valve is closed. FIGURE 3–2
3. Use an 11/16-in wrench to remove bleed valve (8) from (7) HP fuel filter. FIGURE 2–5
FIGURE 3–5. (7) HP fuel filter, (8) bleed valve
3. Defueling Procedure
Verify (9) HP fuel gauge on (1) fuel fill panel reads approximately zero before proceeding. FIGURE 3–1
1
FRONT
9
4
5
6
FRONT
Store (8) bleed valve in a clean, dry plastic bag for reinstallation later.
8
7
FRONT
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4. Select defuel hose adaptor from defueling service kit, CNG – Hexagon Agility p/n 69500019. FIGURE 2–6
FIGURE 3–6. Defuel hose adaptor components
5. Remove fitting from defuel hose adaptor using a pair of 11/16-in wrenches. FIGURE 3–6 Verify fitting O-ring and sealing surfaces are clean and free of debris. Apply a light coat of O-ring lubricant to fitting O-ring before installing in HP fuel filter bowl port.
6. Install fitting in (7) HP fuel filter bowl port (circled) using a 5/8-in socket or crows foot wrench. FIGURE 3–7
FIGURE 3–7. (7) HP fuel filter, filter bowl drain port (red oval), fitting
Verify defuel hose adaptor NGV valve is closed.
NOTE: Defuel hose adaptor shown shortened for clarity.
NGV valve
Inspect defuel hose adaptor NGV connector O-ring (not visible) for damage; replace if necessary.
fitting
FRONT
7
Torque fitting to 25 ft-lbs (33.9 Nm).
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7. Attach defuel hose adaptor end to fitting using a 5/16-in wrench and a 11/16-in wrench. FIGURE 3–8
FIGURE 3–8. (7) HP fuel filter with fitting and defuel hose adaptor attached
8. Attach fuel facility ground cable clips to the following locations: (a) known good vehicle ground, (b) vent stack ground, and, if present, connect (c) third ground cable clip to a dedicated ground rod. FIGURE 2–9
FIGURE 3–9. Ground cable clip attachment locations
Tighten hose fittings according to Appendix A: WI.0199 Removal and Retightening of Tube Fittings.
defuel hose adaptor end
fitting
7
FRONT
vent stack/pipe
– properly supported,
minimum 10-ft (3 m) above ground
grounding rod
– minimum 8-ft
(2.44 m) deep
To rest of fuel system
ground cable clips
ground cable
(vehicle)
HP filter
defuel adaptor hose
ground cable clip
a
b
c
Always follow federal, state, local, and fuel facility rules and guidelines.
If fuel facility ground cable is not present, use ground cable from Hexagon Agility® defueling service kit, CNG, p/n 69500019.
Always ground vehicle and vent stack when defueling.
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9. Attach connector end of defuel hose to vent stack receptacle. NOTE: Use Hexagon Agility® defuel hose p/n 20100021 if hose is not provided. FIGURE 3–10
FIGURE 3–10. Defuel hose adaptor; defuel hose NGV connector end attached to vent stack receptacle
10. Open (5) DS cylinder manual shutoff valve. NOTE: Cylinder shield not shown. FIGURE 3–11
FIGURE 3–11. (4) 1/4-turn manual shutoff valve, (5) DS cylinder manual valve, (6) PS cylinder manual valve
11. Open (6) PS cylinder manual shutoff valve. NOTE: Cylinder shield not shown. FIGURE 3–12
(vehicle)
HP filter
Verify defuel hose adaptor NGV valve is closed.
NGV connector
vent stack manual valve
NGV valve
defuel hose
To rest of fuel system
defuel hose adaptor
FRONT
4
5
6
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12. Spray Swagelok Snoop® on all defuel hose adaptor fitting connections FIGURE 3–12
FIGURE 3–12. (7) HP fuel filter, fitting, defuel receptacle, NGV valve, defuel hose adaptor connections (circled) to be leak checked
13. SLOWLY open 1/4-turn manual shut off valve and wait 3 minutes to check for bubbles as a sign of a leak. FIGURE 3–13
FIGURE 3–13. (4) 1/4-turn manual shutoff valve in the OPEN position
If a leak is found:
a. Close 1/4-turn manual shutoff valve. FIGURE 3–14
FIGURE 3–13. 1/4-turn manual shutoff valve in CLOSED position
defuel hose adaptor end
fitting
7
FRONT
NGV valve
defuel receptacle
FRONT
4
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b. Disconnect defuel adaptor hose from defuel hose. FIGURE 3–14
FIGURE 3–14. Defuel adaptor hose, NGV valve, defuel hose
c. SLOWLY open defuel adaptor hose NGV valve. FIGURE 3–14
d. Tighten fitting(s) according to Appendix A: WI.0199 Removal and Retightening of Tube Fittings (below).
FIGURE 3–14. (7) HP fuel filter, fitting, defuel receptacle, NGV valve, defuel hose adaptor fitting connections (circled) to be tightened
e. Once repair is complete, open 1/4-turn manual shutoff valve and proceed to Step 16. FIGURE 3–16
FIGURE 3–16. 1/4-turn manual shutoff valve in OPEN position
14. SLOWLY open defuel hose adaptor NGV valve. FIGURE 3–14
(vehicle)
HP filter
NGV valve
defuel hose
To rest of fuel system
defuel hose adaptor
Allow all pressure to be released before proceeding.
fitting
7
FRONT
NGV valve
defuel receptacle
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FIGURE 3–14. Defuel hose NGV connector end attached to vent stack manual valve
15. SLOWLY open vent stack manual valve. FIGURE 3–14
16. Monitor system fuel level on (1) fuel fill panel (9) HP fuel gauge until it reads zero. FIGURE 3–15
FIGURE 3–15. (1) fuel fill panel, (9) HP fuel gauge
17. Disconnect NGV connector end of defuel hose from vent stack receptacle. FIGURE 3–16
FIGURE 3–16. Defuel hose adaptor NGV valve, defuel hose, NGV connector, vent stack receptacle
18. Disconnect defuel hose adaptor from defuel hose. FIGURE 3–16
(vehicle)
HP filter
vent stack manual valve
NGV valve
defuel hose
To rest of fuel system
If defueling rate is too rapid, the excess flow valve will close and prevent defueling. Wait approximately five minutes for excess flow valve to reset and adjust defuel hose adaptor NGV valve for lesser flow before resuming defuel.
defuel hose adaptor
1
FRONT
9
(vehicle)
HP filter
vent stack receptacle
NGV valve
defuel hose
To rest of fuel system
NGV connector
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19. If using fuel facility ground cable: Detach ground cable clips (locations circled) from vehicle ground and vent stack ground and proceed to Step 23. FIGURE 3–17
FIGURE 3–17. Ground cable clip locations: (a) vehicle, (b) grounding rod, (c) vent stack
20. If using ground cable from Hexagon Agility p/n 69500019 defuel kit: Detach ground cable clips (locations circled) from vehicle ground, grounding rod (if present), and vent stack ground. FIGURE 3–17
21. Remove fitting from defuel hose adaptor end using a. FIGURE 3–18
FIGURE 3–18. (7) HP fuel filter, fitting, defuel hose adaptor end
22. Use a 5/8-in wrench to remove fitting from (7) HP fuel filter. FIGURE 3–18
23. Reattach fitting to defuel hose adaptor using a 5/8-in wrench and an 11/16-in wrench. FIGURE 3–18
24. Retrieve (8) bleed valve (stored earlier) and inspect O-ring for damage or wear. FIGURE 3–19
(vehicle)
HP filter
ground cable
To rest of fuel system
ground clip
vent stack
ground clip
grounding rod
a
b
c
defuel hose adaptor end
fitting
7
FRONT
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FIGURE 3–19. (8) bleed valve, O-ring
25. Apply O-ring lubricant to (8) bleed valve O-ring. FIGURE 3–19
26. Use an 11/16-in wrench to reinstall (8) bleed valve in (7) HP fuel filter bowl port (circled). FIGURE 3–20
FIGURE 3–20. (7) HP fuel filter, (8) bleed valve
27. Close (8) bleed valve pressure port relief nut finger tight. FIGURE 3–21
FIGURE 3–21. (8) bleed valve, pressure relief nut
28. Use a 7/16-in wrench to tighten (8) bleed valve pressure port relief nut. FIGURE 3–21
Replace bleed valve if O-ring is damaged.
O-ring
8
Apply O-ring lube to bleed valve (8) O-ring.
Torque bleed valve (8) to 25 ft-lbs (33.9 Nm).
7
8
pressure relief nut
FRONT
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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29. Install pressure relief port cap on (8) bleed valve pressure relief port and bleed valve cap and pressure relief nut. FIGURE 3–22
FIGURE 3–22. (7) HP fuel filter, (8) bleed valve, pressure relief port cap, pressure relief nut cap
30. Vehicle is now defueled and all removed components have been reinstalled; perform repairs as required before performing a leak test on the fuel system.
pressure relief nut cap
pressure relief port cap
7
8
Pressure relief port cap and pressure relief nut cap must be installed to prevent foreign object debris (FOD) intrusion. If cap(s) are not present, please contact Hexagon Agility® Customer Care and Technical Services for replacement.
Leak test (below) must be performed before vehicle may be cleared for operation.
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1. Verify DS manual cylinder valve is open. FIGURE 4–1
FIGURE 4–1. (4) 1/4-turn manual shutoff valve, (5) DS cylinder manual valve
2. Fuel vehicle to 500 psi (3.45 MPa). Refer to ENP-516, Truck and Tractor CNG Fuel System Operation, Maintenance & Inspection Manual, “CNG System Fueling” section. FIGURE 4–2
FIGURE 4–2. (1) fuel fill panel, (9) HP gauge, fuel fill receptacle, Drive Away Protection (DAP) cap, NOTE: cap removed
3. Open 1/4-turn manual shutoff valve. FIGURE 4–3
FIGURE 4–3. Fuel fill panel, (9) HP gauge reading 500 psi, (4) 1/4-turn manual shutoff valve, (5) DS cylinder manual valve
4. While observing HP gauge on fuel fill panel, have an assistant SLOWLY open the DS cylinder manual valve until it reads 500 psi (3.45 MPa) then direct the assistant to close the DS cylinder manual valve. FIGURE 3–3
4. Leak Test Procedure
FRONT
4
5
1
9
fuel fill receptacle
DAP cap
FRONT
1
FRONT
4
5
9
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5. Listen for hissing as a sign of a system leak.
6. Apply Swagelok® Snoop® leak detection solution to all fuel system connections and wait 3 minutes. FIGURE 4–4
FIGURE 4–4. Swagelok® Snoop®, bubbles forming at a fitting junction
7. Inspect all fuel system junctions for bubbles as an indicator of a leak. FIGURE 3–4
a. If no leaks are found, proceed to next step.
b. If a leak is found, depressurize fuel system. Refer to Section 2 (above).
c. 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.
8. Fuel vehicle to 1800 psi (12.4 MPa). FIGURE 3–5. Refer to ENP-516, Truck and Tractor CNG Fuel System Operation, Maintenance & Inspection Manual, “CNG System Fueling” section.
FIGURE 4–5. Fuel fill panel, (9) HP gauge reading 1800 psi, (4) 1/4-turn manual shutoff valve, (5) DS cylinder manual valve
9. Repeat Steps 6 and 7 until no leaks are present, then proceed to Step 10.
Swagelok® Snoop® bottle
Bubble formation indicative of a fitting leak
1
FRONT
4
5
9
NEVER attempt to tighten fittings while system is pressurized.
STOP fuel fill immediately if loud hissing indicative of a fuel system leak is audible.
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10. Fuel vehicle to 3600 psi (24.6 MPa). FIGURE 4–6. Refer to fuel Refer to ENP-516, Truck and Tractor CNG Fuel System Operation, Maintenance & Inspection Manual, “CNG System Fueling” section.
FIGURE 4–6. Fuel fill panel, (9) HP gauge reading 3600 psi, (4) 1/4-turn manual shutoff valve, (5) DS cylinder manual valve
11. Repeat Steps 6 through 7 until no leaks are present, then proceed to Step 12.
12. When the system passes the 3600 psi (24.6 MPa) leak test, use shop rags to clean all Swagelok® Snoop® from fuel system components.
13. 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
14. Install pressure relief port cap, p/n 61090128, and bleed valve cap, p/n 61090129, on (v) pressure relief port and (8) bleed valve. FIGURE 4–8
FIGURE 4–8. (7) HP fuel filter bowl, (8) bleed valve, (v) pressure relief port, pressure relief port cap, pressure relief nut cap
15. Road test vehicle using the procedure described below.
1
FRONT
4
5
9
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
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1. Verify 1/4-turn manual shutoff valve, DS manual cylinder valve, and PS manual cylinder valve, are open. FIGURE 5–1
FIGURE 5–1. (1) DS manual cylinder valve, (2) PS manual cylinder valve, (3) 1/4-turn manual shutoff valve
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 leak or system fault appears, contact Hexagon Agility® CCTS.
6. If system is operating properly, release vehicle into service.
7. Update vehicle maintenance and repair records.
5. Road Test Procedure
3
1
2
FRONT
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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
[email protected]
Parts Orders
[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 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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