Maintenance Manual HYDRANT SHUTOFF VALVE F352 / F353 SERIES

Transcription

1 Maintenance Manual HYDRANT SHUTOFF VALVE F352 / F353 SERIES NOTICE: PROPRIETARY INFORMATION OF WHITTAKER CONTROLS, INC., A BUSINESS UNIT OF MEGGITT PLC. THE INFORMATION CONTAINED IN THIS DOCUMENT IS DISCLOSED IN CONFIDENCE. IT IS THE PROPERTY OF WHITTAKER CONTROLS, AND SHALL NOT BE USED, DISCLOSED TO OTHERS, OR REPRODUCED IN WHOLE OR IN PART WITHOUT THE EXPRESS WRITTEN CONSENT OF WHITTAKER CONTROLS. IF CONSENT IS GIVEN THIS NOTICE SHALL APPEAR IN ANY SUCH REPRODUCTION. REVISION /01/2005

2 LIST OF EFFECTIVE PAGES On a revised page, the portion of text or illustrations affected by the change is indicated by a vertical line in the outer margin of the page. When a revision is issued, the entire document is reissued with the current revision number and date shown on all pages. For major revisions, the basic number is incremented. For minor revisions, the number following the decimal is incremented. Dates of issue for original and subsequent revisions are as follows: Original /15/2004 Revision /01/2005 The total number of pages in this technical document is 38 consisting of the following: Title, A, 1 36 TABLE OF CONTENTS SUBJECT PAGE Introduction... 1 Description and Operation... 1 Fault Isolation... 7 Maintenance Cleaning Inspection Testing and Adjustment Illustrated Parts List GROUND FUELING PRODUCTS GROUP Revision /01/2005 Page A

3 INTRODUCTION 1. General This manual provides component maintenance shop instructions for the Hydrant Shutoff Valve (valve). 2. Revision Service This manual will be revised as necessary to show the current information. 3. Weights and Measurements Weights and measurements in this manual are expressed in both English (U.S. customary) and Metric (SI) units. 1. Description DESCRIPTION AND OPERATION The Hydrant Shutoff Valve (valve) (see Figure 1) provides the means of controlling ON/OFF flow control in aircraft refueling operations. The valve inlet is connected to the riser flange of the underground fuel piping. The outlet adapter mates with a hydrant coupler or coupler/regulator attached to a hose supplying or receiving fuel. The installed hydrant valve forms a pressure tight ON/OFF connection between the refueling system and fuel supply source. The major functional components of the valve are the outlet adapter, the pressure relief valve, the poppet, the servo assembly, the servo assembly, the maintenance valve, the piston, the inner chamber, and the valve body. 2. Installing the Hydrant Coupler on the Hydrant Shutoff Valve When a suitable hydrant coupler is connected to the outlet adapter, opening the hydrant coupler will first open the relief valve plunger in the poppet and then will push the main poppet open. The relief valve relieves pressure in the valve body to allow easy opening of the main poppet. 3. Operation A. With the servo not actuated, inlet pressure is applied to the inside of the piston chamber, holding it in its closed position. B. When the servo is actuated, pressure inside the piston chamber is relieved downstream and upstream pressure opens the piston. When the servo is de-activated, the downstream bleed is shut off, allowing upstream pressure to build behind the piston, forcing it closed. GROUND FUELING PRODUCTS GROUP Revision /01/2005 Page 1

4 Figure 1. Hydrant Shutoff Valve (Series F353 Shown) 4. Leading Particulars (Refer to Table 1) Table 1. Leading Particulars Service...Automotive and Aviation Fuels Operating Pressure Maximum Working psi (13,8 bar) Proof psi (19,0 bar) Pressure Drop (connected to F240 or F250 Hydrant Coupler) (approximate) psi at 1200 US gpm (1,0 bar at l/m) Operating Times Opening... 5 to 10 seconds Closing... 2 to 5 seconds GROUND FUELING PRODUCTS GROUP Revision /01/2005 Page 2

5 Table 1. Leading Particulars (continued) Fluid Temperature to 160 F ( 54 to 71 C) Ambient Temperature to 160 F ( 54 to 71 C) Envelope Dimensions... Refer to Figure 2 Weights (approximate) F pounds (40 kg) F pounds (27,5 kg) 5. Model Variations The valves conform to API Standard 1584, 2nd Edition dated December 1994, and IP Standard for Aviation Hydrant Pit Systems, Recommended Arrangements for New Facilities, dated August Figure 1 shows the basic F352 and F353 versions. The F352 inlet mates with a 6-inch, 300-pound, ANSI R/F flange. The F353 inlet mates with a 4-inch, 150-pound, ANSI R/F flange. Both of the valve versions comply with API Standard Refer to Table 2 for the available valve variations. Refer to the ILLUSTRATED PARTS LIST section for additional details. GROUND FUELING PRODUCTS GROUP Revision /01/2005 Page 3

6 Table 2. Model Variations MOD LETTERS F352 F353 DESCRIPTION Baseline F352EM Standard hydrant shutoff valve per IP specification lanyard operated shutoff, 6-inch ANSI inlet, 4-inch API outlet, 5 mm mesh inlet strainer, epoxy coated ductliron body Baseline F353EM A C D F Standard hydrant shutoff valve lanyard operated shutoff, 4-inch ASA inlet, 4-inch API outlet, epoxy coated ductliron body Adds 20 mesh strainer at split-line of outlet adapter Adds product selection screws in Position 4 (moveable) Substitutes air operated servo with plug inlet similar to F554 (per API Bulletin 1584) (used with F587) Substitutes air operated servo (50 psi minimum, 1/4-28 NPT connector) G Adds 10 mesh strainer K Changes valve body to 6-inch ANSI 300# version L Changes valve body to 6-inch ANSI 150# version N P Substitutes epoxy coated outlet adapter Adds lanyard operated override (for Mods E and F only) GROUND FUELING PRODUCTS GROUP Revision /01/2005 Page 4

7 Figure 2. Hydrant Shutoff Valve Envelope Dimensions (Sheet 1 of 2) GROUND FUELING PRODUCTS GROUP Revision /01/2005 Page 5

8 Figure 2. Hydrant Shutoff Valve Envelope Dimensions (Sheet 2 of 2) GROUND FUELING PRODUCTS GROUP Revision /01/2005 Page 6

9 FAULT ISOLATION 1. General Refer to Table 3 for fault isolation information. Locate suspected faulty component and take appropriate remedial action. Table 3. Fault Isolation FAULT POSSIBLE CAUSE CORRECTIVE ACTION No fuel flow Hydrant coupler closed Open the hydrant coupler. Downstream system shut off Open the downstream system. Maintenance valve closed Open the maintenance valve stem (20, IPL Figure 1). Valve will not close Servo assembly (7) not actuated Servo assembly (13) not actuated Piston (6) jammed by contamination Tube (48) incorrectly installed or damaged Servo assembly (13) not de-activated, air pressure trapped in servo Servo valve ball (33) will not unseat Piston (6) jammed by contamination Piston seal (14) excessively worn or damaged Actuate the servo by pulling the lanyard. Actuate the servo by applying 70 psi (4,8 bar) air pressure. Attempt to cycle the valve 3 or 4 times to clear any loose contamination. If not successful, overhaul the valve. Reinstall the tube. If damaged, replace the tube. Relieve air pressure from the servo. Replace the servo ball (refer to MAINTE- NANCE paragraph 9). Attempt to cycle the valve 3 or 4 times to clear any loose contamination. If not successful, overhaul the valve. Overhaul the valve. GROUND FUELING PRODUCTS GROUP Revision /01/2005 Page 7

10 Table 3. Fault Isolation (continued) FAULT POSSIBLE CAUSE CORRECTIVE ACTION Valve will not close (continued) Hot valve Valve not fully closed when not actuated Leakage past relief valve poppet plunger (5) Leakage around poppet (4) Valve opens or closes too slowly Valve opens or closes too slowly (continued) Valve opens or closes too fast Tube (18) damaged Piston (6) jammed by contamination Piston (6) not seating fully due to contamination on seat Servo valve ball (33) will not seat Tube (18) damaged Relief valve poppet plunger (5) or seat (45) excessively worn or damaged Contamination on seat or seat excessively worn or damaged Metering pin (17) incorrectly adjusted for the system flow and pressure Contamination in the orifice of piston (6), or on the metering pin (17). Metering pin (17) incorrectly adjusted for the system flow and pressure Overhaul the valve. Attempt to cycle the valve 3 or 4 times to clear any loose contamination. If not successful, overhaul the valve. Attempt to cycle the valve 3 or 4 times to clear any loose contamination. If not successful, overhaul the valve. Replace the servo ball (refer to MAINTE- NANCE paragraph 9). Replace the tube (refer to MAINTE- NANCE paragraph 12). Remove and clean the parts. Replace if worn or damaged (refer to MAINTE- NANCE paragraph 7). Remove and clean the parts. Replace if worn or damaged (refer to MAINTE- NANCE paragraphs 7). Make sure that the slow operating time is not due to other system functions. Then, adjust the metering pin (refer to MAINTENANCE paragraph 13). Attempt to cycle the valve 3 or 4 times to clear any loose contamination. If not successful, overhaul the valve. Make sure that the slow operating time is not due to other system functions. Then, adjust the metering pin (refer to MAINTENANCE paragraph 13). GROUND FUELING PRODUCTS GROUP Revision /01/2005 Page 8

11 Table 3. Fault Isolation (continued) FAULT POSSIBLE CAUSE CORRECTIVE ACTION Hydrant coupler is difficult to open Hydrant coupler is difficult to close Piston (6) jammed by contamination Piston (6) not seating fully due to contamination on seat Servo valve ball (33) will not seat Tube (18) damaged Poppet relief valve plunger (5) not actuated due to contamination Poppet relief valve plunger (5) not actuated due to hydrant coupler poppet shape. Pressure trapped downstream of hydrant coupler Attempt to cycle the valve 3 or 4 times to clear any loose contamination. If not successful, overhaul the valve. Attempt to cycle the valve 3 or 4 times to clear any loose contamination. If not successful, overhaul the valve. Replace the servo ball (refer to MAINTE- NANCE paragraph 9). Replace the tube (refer to MAINTE- NANCE paragraph 12). Remove and clean the plunger. Replace if damaged or excessively worn. (Refer to MAINTENANCE paragraph 7.) Use the correct hydrant coupler (with the required poppet type). Check the downstream pressure and correct as necessary. Check functioning of the hydrant coupler relief valve (if equipped). GROUND FUELING PRODUCTS GROUP Revision /01/2005 Page 9

12 MAINTENANCE WARNING: ONLY THE ADAPTER, THE SERVO, THE STRAINER, AND THE BALL MAY BE SER- VICED WITH THE VALVE INSTALLED AND UNDER PRESSURE. BEFORE SERVICING ANY PART OF THIS VALVE, THE MAINTENANCE VALVE (20) MUST BE CLOSED AND PRESSURE IN THE ADAPTER (2) MUST BE COMPLETELY RELIEVED. SEE PARAGRAPH 6. FOR MAXIMUM SAFETY, DEPRESSURIZE THE UPSTREAM SYSTEM. 1. Overhaul Parts Kits Refer to the ILLUSTRATED PARTS LIST section for the Overhaul Parts Kit information. 2. Recommended Maintenance Materials Refer to Table 7 for recommended assembly materials. Suitable equivalent materials may be substituted for the items listed. Table 7. Recommended Assembly Materials DESCRIPTION SPECIFICATION SOURCE Lubricant Molycote 33 Commercially available (Dow Corning) (for air servo packing only) Petrolatum Commercially available Thread Locking Compound Loctite 262 Commercially available (Loctite Corporation) (for mechanical servo screw only) 3. Lubrication During maintenance, apply a light coating of petrolatum (petroleum jelly) on all of the packings (except packing (13B, IPL Figure 1)) prior to installation, to facilitate installation and prevent damage to the packings. GROUND FUELING PRODUCTS GROUP Revision /01/2005 Page 10

13 4. Removing the Hydrant Shutoff Valve from the System (Refer to IPL Figure 1) WARNING: THE VALVE MUST BE REMOVED FROM THE SYSTEM BEFORE ANY OF THE SERVICING IN PARAGRAPH 12 OR 13 IS PERFORMED. A. Remove all pressure from the valve inlet by shutting down the pumps or closing the riser valve. B. Actuate the manual (mechanical) servo or apply air pressure to the air-operated servo, to set the valve to its OPEN position. C. Do NOT close the maintenance valve (20). D. Release the pressure in the adapter (2) by depressing relief valve (5) in the poppet (4) until flow stops. Place a cloth or towel on top of the adapter to contain any fuel spray. WARNING: IF FUEL FLOW DOES NOT STOP AFTER 5 OR 6 SECONDS, STOP. THE VALVE INLET HAS NOT BEEN DEPRESSURIZED. THE RISER OR OTHER VALVES MAY NOT BE SEALING. TURN OFF THE LINE PUMPS. E. Remove the mounting flange bolts. F. Remove the air pressure from the air servo or actuate the mechanical servo to its CLOSED position. Lift the valve out. Remove the gasket(s) and the stone guard (if installed) from the riser flange. 5. Installing the Hydrant Shutoff Valve (Refer to IPL Figure 1) CAUTION: When installing on a new system, the system MUST be flushed dean BEFORE valve installation. Excessive contamination may damage sealing surfaces. A. Clean the riser flange face. B. Install new gasket(s) on the riser flange. C. Install the valve on the riser flange. Make sure that the gasket(s) and the stone guard (if installed) are correctly positioned. D. Install the flange bolts, nuts and washers (if required). E. Torque the flange nuts evenly to the users specification. The recommended minimum torque for 4-inch flanges is 80 pound-feet (110 Nm). The recommended minimum torque for 6-inchflanges is 150 pound-feet (205 Nm). F. Close the maintenance valve (20) (maximum torque is 50 pound-inches (5,7 Nm). GROUND FUELING PRODUCTS GROUP Revision /01/2005 Page 11

14 G. Apply pressure to the valve by turning on the pumps and opening the riser shutoff valve. H. Make sure that there is no flange leakage. I. Fully open the maintenance valve (20). J. Connect a hydrant coupler to the valve and operate the hydrant on-and-off 6 or 7 times, to expel any air from the piston chamber. K. Set the servo CLOSED. Remove the hydrant coupler. L. Check for any leakage. Press the plunger (5). The flow should stop after 5 or 6 seconds. m. Install the protective cover on the outlet. 6. Removing and Replacing the Servo Assembly (Refer to IPL Figure 1) A. For a mechanical servo (7), set it to its CLOSED position. For an air servo, make sure that that the air pressure is relieved. B. Close the maintenance valve (20) (maximum torque is 50 pound-inches (5,7 Nm). C. Relieve the pressure in the adapter (2) by pressing the relief valve plunger (5) in the poppet (4) until the flow stops. Place a cloth or towel on top of the adapter to contain any fuel spray. WARNING: IF FUEL FLOW DOES NOT STOP AFTER 5 OR 6 SECONDS, STOP. THE VALVE INLET HAS NOT BEEN DEPRESSURIZED. THE VALVE MUST BE REMOVED FROM THE SYSTEM FOR OVERHAUL. D. Press one side of the poppet (4) and insert a plastic rod or a large section packing to keep poppet open. E. Remove the two screws (41). F. Remove the clamp (40) and the servo (7 or 13). G. Clean the servo seating area and the base of the servo. The base of the servo may be lightly lubricated with petrolatum. H. Install the servo (7 or 13) on the projecting boss of the valve body (1). Install the clamp (40) over the servo body, visually aligning the screw holes in the clamp and adapter flange. I. Install the two screws (41), securing the protective cover lanyard with one of the screws. Torque the screws to 75 pound-inches (8,6 Nm). Fully open maintenance the valve (20). GROUND FUELING PRODUCTS GROUP Revision /01/2005 Page 12

15 7. Removing and Replacing the Outlet Adapter, the Poppet, and the Strainer (Refer to IPL Figure 1) A. Remove the servo (refer to paragraph 6 above). B. Remove the eight screws (34). C. The adapter can now be removed. The adapter is internally guided and must be lifted straight upward. To break adapter seal, one of screws may be put back in its threaded hole and used as a jack screw. Remove the screw after use. D. Remove the poppet (4) and the spring (9). Remove packing (11). E. If the strainer (37) is installed, it may be removed now. Remove the retaining ring (43) and the spacer (47). Then, lift out the strainer (37). WARNING: DO NOT REMOVE THE RETAINING RING (44) WITH THE VALVE INSTALLED IN A PIT. F. Remove the tube (48) for cleaning. G. Clean all of the parts (refer to the CLEANING section). H. When all of the parts have been cleaned, check them for defects (refer to the INSPECTION section). H. Install the tube (48) in the valve body (1) with its open end pointed straight upward. I. If the strainer (37) is being installed, slide it over the top of the piston chamber (3) and the tube (48) and install the spacer (47) on top of the strainer. J. Install the retaining ring (43) (must always be installed). K. Install the spring (9) in the top of the inner chamber (3). Balance the poppet (4) on top of the spring (9). L. Make sure that the tube (48) is pointing straight upward. M. Lubricate a new packing (11) with petrolatum. Install the packing over the boss on the adapter flange (2). N. Rotate the outlet adapter (2) to align notch in flange with the servo boss on the body (1). Slide the outlet adapter straight downward over the top of inner chamber (3), and do not rotate it until the packing (11) is seated in the valve body (1). GROUND FUELING PRODUCTS GROUP Revision /01/2005 Page 13

16 O. Make sure that the packing (11) is correctly positioned and has not fallen off of the boss and become trapped. If the packing is incorrectly positioned, the flange joint will leak. P. Make sure that the tube (48) is still pointed straight upward, by pressing the poppet (4) and looking inside of the outlet adapter (2). Q. Install the eight screws (34) and tighten them down evenly. Torque the screws to 150 poundinches (17,2 Nm). R. Re-install the servo (7 or 13) (refer to paragraph 6 above). 8. Overhauling the Pressure Relief Valve (Refer to IPL Figure 1) A. Remove the poppet (4) (refer to paragraph 7 above). B. Unscrew the shaft (15). Hold the poppet in a padded vise. Be careful not to damage the poppet sealing surface. C. Remove the spring (10), the plunger (5) and the gasket (45). D. Clean all of the parts, giving particular attention to the threads of the poppet (4) and the shaft (15) (refer to the CLEANING section). E. When all of the parts have been cleaned, check them for defects (refer to the INSPECTION section). F. Install a new gasket (45) in the poppet (4), making sure that it is seated flatly. G. Install the plunger (5) and the spring (10). H. Apply 2 drops of thread locking compound (Loctite 262) to the threads of the shaft (15). Install the shaft in the poppet (4). Torque the poppet to 50 pound-inches (5,7 Nm). I. Re-assemble the outlet adapter (refer to paragraph 7 above). 9. Overhauling the Servo Valve (Refer to IPL Figure 1) A. Remove the servo (refer to paragraph 6 above). B. Remove the retaining ring (30). C. Using two flat blade screwdrivers as levers (see Figure 3), lift out the seat (19). D. Remove the plunger (31) and the packing (28) from inside of the seat (19). Remove the packing (28) from the plunger. GROUND FUELING PRODUCTS GROUP Revision /01/2005 Page 14

17 Figure 3. Removing the Servo Valve Seat E. Remove the packings (22 and 24) from the seat. F. Lift the ball (33) and the spring (39) out of the valve body (1). G. Do not remove the plug (32) or the plug (23) (if installed). H. Clean all parts thoroughly, removing any contamination build-up (refer to the CLEANING section). NOTE: All of the packings must be replaced. I. When all of the parts have been cleaned, check them for defects (refer to the INSPECTION section). J. Install the spring (39) and the ball (33) in the valve body (1). K. Lubricate two new packings (22 and 24) with petrolatum. Install the packings on the seat (19). L. Install the seat (19) in the valve body (1) and secure it with the retaining ring (30). NOTE: If the valve body is full of fuel, it is necessary to prevent the ball from sealing on the seat. A 3/16-inch (5 mm) diameter rod can be inserted through the hole in the top of the seat. M. Lubricate a new packing (28) with petrolatum. Install the packing on the plunger (31). N. Refer to Figure 4 and install the plunger (19) in the seat (19), long end first. O. Install the servo (7 or 13) (refer to paragraph 6 above). GROUND FUELING PRODUCTS GROUP Revision /01/2005 Page 15

18 Figure 4. Installing the Servo Valve Plunger 10. Overhauling the Mechanical Servo Assembly (Refer to Figure 5 and IPL Figure 1) A. Remove the servo (refer to paragraph 6 above). B. Drive out the upper 1/8-inch (3,2 mm) diameter pin (7G). Lift the lever (7F) and remove pedal shaft assembly (items 7A, 7B, 7C and 7E). Remove the spring (7D). C Hold the shaft (7E) and remove the screw (7A) and the washer (7B). Separate the pedal (7C) and shaft (7E). D. Drive out the lower 1/8-inch (3,2 mm) diameter pin (7G). Remove the lever (7F). E. Drive out the middle 1/8-inch (3,2 mm) diameter pin (7G). Remove the spring (7J). F. Clean all of the parts thoroughly (refer to the CLEANING section). G. When all of the parts have been cleaned, check them for defects (refer to the INSPECTION section). H. Install the spring (7j) and the middle pin (7G). Install the lever (7F) and the upper pin (7G). I. Hold the shaft (7E) and put the pedal (7C) in position. Apply one drop of thread locking compound (Loctite 262) on the screw (7A). Install the screw and the washer (7B) in the shaft and tighten it securely. J. Install the spring (7D) and the shaft (7E) in the body (7H). Press inward on the shaft until the lever latches. Install the lower pin (7G). GROUND FUELING PRODUCTS GROUP Revision /01/2005 Page 16

19 Figure 5. Mechanical Servo Assembly J. Make sure that the pedal (7C) latches securely when pressed, and that it releases when the lever is lifted. K. Install the servo (7) (refer to paragraph 6 above). 11. Overhauling the Air Servo Assembly (Refer to Figure 4 and IPL Figure 1) A. Remove the servo (refer to paragraph 6 above). B. Push the retainer (13E) into the cylinder (13A) and remove the ball (13F). C. Slowly allow the spring (13D) to push the retainer (13E) out of the cylinder (13A). Remove all of the components from the cylinder. D. Remove the packing (13B) from the piston (13C). E. Clean all of the parts thoroughly (refer to the CLEANING section). F. When all of the parts have been cleaned, check them for defects (refer to the INSPECTION section). GROUND FUELING PRODUCTS GROUP Revision /01/2005 Page 17

20 Figure 6. Air Servo Assembly G. Lubricate a new packing (13B) with lubricant (Molycote 33). Install the packing in the packing groove of the piston (13C). H. Install the piston (13C) in the cylinder (13A). I. Install the spring (13D) and the retainer (13E) in the cylinder (13A). J. Push the retainer (13E) into the cylinder (13A) to expose the ball groove. Insert the ball (13F). Release the retainer to trap the ball. K. Install the servo (13) (refer to paragraph 6 above). WARNING: ONLY THE SERVICING OUTLINED IN PARAGRAPHS 6 THROUGH 11 ABOVE CAN BE PERFORMED WITH THE VALVE INSTALLED. 12. Overhauling the Maintenance Valve WARNING: THE VALVE MUST BE REMOVED FROM THE SYSTEM TO PERFORM THIS REPAIR TASK. A. With the valve on a bench, fully open the maintenance valve (20). B. Using a deep 1-inch (25,4 mm) hex socket, remove the maintenance valve (20) from the valve body (1). GROUND FUELING PRODUCTS GROUP Revision /01/2005 Page 18

21 C. Drive out the pin (42). Unscrew the stem (20) from the tube (18). Ball (38) will be free for removal. D. Remove all of the packings (24, 25, 26 and 27). E. Clean all of the parts thoroughly (refer to the CLEANING section). F. When all of the parts have been cleaned, check them for defects (refer to the INSPECTION section). G. Lubricate the new packings (24, 25, 26 and 27) with petrolatum. CAUTION: Make sure that the packings are seated correctly (not twisted). H. Lubricate the packing contact surface with petrolatum and the internal threads of the tube (18). I. Put the ball (38) inside of the tube (18). Screw the stem (20) inward by hand until it touches the ball. CAUTION: If the inner chamber is not correctly aligned, tube (18) could be bent or broken. J. Drive the pin (42) into its bore. Unscrew the stem (20) by hand until it touches pin (42). Before installing the maintenance valve in the valve body (1), look into the side port and make sure that the port in the inner chamber (3) is lined up with the side port. Rotate the inner chamber in the valve body as necessary to achieve accurate alignment. The alignment pin (P/N ) may be used to check the alignment. K. Using petrolatum, lubricate the parts and the threads in the valve body (1), the inner chamber (3) and the maintenance valve (20). L. Install the maintenance valve (20) in the valve body (1). Torque the maintenance valve to 50 pound-inches (5,7 Nm). 13. Overhauling the Piston and Inner Chamber WARNING: THE VALVE MUST BE REMOVED FROM THE SYSTEM TO PERFORM THIS REPAIR TASK. A. With valve on a bench, fully open the maintenance valve (20). B. Remove the servo (refer to paragraph 6 above). C. Remove the outlet adapter, the poppet and the strainer (refer to paragraph 7 above). D. Using a deep 1-inch (25,4 mm) hex socket, remove the maintenance valve (20) from the valve body (1). GROUND FUELING PRODUCTS GROUP Revision /01/2005 Page 19

22 E. Refer to Figure 7 and measure and write down Dimension M, the position of the metering pin (17) in the inner chamber (3). This measurement is required to make sure that the adjustment of the valve is retained. F. Turn the valve body (1) on its side. Remove the retaining ring (44) and lift the inner chamber (3) out of the valve body. CAUTION: The piston (6) may or may not remain in the inner chamber (3). Do not allow the piston to drop or fall and be damaged. G. Remove the piston (6) from the inner chamber (3). If the piston does not come out easily when pulled by hand, remove the nut (35), the washers (36 and 46) and the metering pin (17). Using a plastic or wooden rod, drive the piston out. Do not remove the metering pin (17), unless required to remove the piston,or if the metering pin is damaged. CAUTION: Do not pry or use tools that will damage the polished surfaces. H. Using a soft metal blade remove the seal (14) and the packing (12) from the inner chamber (3). I. Clean all of the parts thoroughly (refer to the CLEANING section). J. When all of the parts have been cleaned, check them for defects (refer to the INSPECTION section). K. Install the metering pin (17), the washers (46 and 36) and the nut (35) in the inner chamber (3). Adjust the position of the metering pin to the Dimension M measured in paragraph E (or 1.20 inches [31,7mm]) if no measurement is available. Lock the metering pin in position with the nut nut (35). Torque the nut to 100 pound-inches (10,5 Nm). Figure 7. Measuring the Metering Pin Position GROUND FUELING PRODUCTS GROUP Revision /01/2005 Page 20

23 L. Lubricate (petrolatum) and install the packing (12) in the seal groove of the inner chamber (3). CAUTION: Make sure that the packings are seated correctly (not twisted). M. Lubricate the seal (14) with petrolatum. Gently roll the seal between your fingers so that it forms a slight U shape. Refer to Figure 8 and insert the seal into the seal groove inside of the inner chamber (3), covering the packing (12) completely. CAUTION: Do not allow seal (14) to crease since this will damage the seal. N. Lubricate the outside diameter of piston (6) with petrolatum. Install the spring (8) and the piston (6) in the inner chamber (3). Apply steady hand pressure and rotate the piston, do not hammer. If the piston does not enter the seal easily, remove the piston and make sure that seal (14) and packing (12) are correctly seated and have not been damaged. O. Press the piston (6) against the spring (8) in the inner chamber. When released, the piston must return. P. Turn the valve body (1) on its side. Insert the inner chamber (3) and the piston (6) into the valve body. Keep the piston in the inner chamber by putting one hand through the seat from the flange end. Q. Push the inner chamber (3) fully downward and install the retaining ring (44). Allow the inner chamber to return, stopping against the retaining ring. Figure 8. Forming the Piston Seal GROUND FUELING PRODUCTS GROUP Revision /01/2005 Page 21

24 CAUTION: If the inner chamber is not correctly aligned, tube (18) could be bent or broken. R. Before installing the maintenance valve in the valve body (1), look into the side port and make sure that the port in the inner chamber (3) is lined up with the side port. Rotate the inner chamber in the valve body as necessary to achieve accurate alignment. The alignment pin (P/N ) may be used to check the alignment. S. Using petrolatum, lubricate the parts and the threads in the valve body (1), the inner chamber (3) and the maintenance valve (20). T. Install the maintenance valve (20) in the valve body (1). Torque the maintenance valve to 50 pound-inches (5,7 Nm). U. Install the outlet adapter, the poppet and the strainer (refer to paragraph 7 above). GROUND FUELING PRODUCTS GROUP Revision /01/2005 Page 22

25 1. Cleaning Materials CLEANING Refer to Table 4 for recommended cleaning materials. Suitable equivalent cleaning materials may be substituted for the items listed. Table 4. Recommended Cleaning Materials DESCRIPTION SPECIFICATION SOURCE Brush, Bristle, stiff, nonmetallic Commercially available Dry Cleaning Solvent P-D-680, Type 2 Commercially available Pick, Teflon Commercially available Plastic Bags Commercially available Tissues, lint-free Commercially available 2. Cleaning Procedures WARNING: DRY CLEANING SOLVENT IS FLAMMABLE AND TOXIC TO EYES, SKIN, AND RESPIRATORY TRACT. SKIN/EYE PROTECTION REQUIRED. AVOID REPEATED/ PROLONGED CONTACT. USE ONLY IN WELL VENTILATED AREAS. GOOD GENERAL VENTILATION IS NORMALLY ADEQUATE. KEEP AWAY FROM OPEN FLAMES OR OTHER IGNITION SOURCES. A. Clean all metal parts by washing thoroughly in dry cleaning solvent. Remove stubborn deposits by scrubbing with a nonmetallic stiff bristle brush. Use a Teflon pick to remove obstructions from ports, grooves and passages. NOTE: All of the parts must be free of corrosion, dirt, grease, oil, or any other foreign matter. WARNING: WEAR EYE PROTECTION WHEN DRYING PARTS WITH COMPRESSED AIR. DO NOT DIRECT AIRSTREAM AT PERSONNEL OR LIGHT METAL PARTS. B. Dry parts with clean lint-free tissues or clean, dry compressed air. C. Package clean parts in plastic bags. GROUND FUELING PRODUCTS GROUP Revision /01/2005 Page 23

26 INSPECTION 1. General A. Under strong light and magnification, visually check all parts in accordance with the general criteria specified in paragraph 2 below. B. Repair minor damage in accordance with local directives. If damage is major or beyond simple repair, replace the part rather than attempt extensive repairs. 2. Component Checks (Refer to Table 5) Table 5. Component Checks DESCRIPTION (IPL Figure 1 Item Number) General CHECK CRITERIA Visually check all parts as applicable for nicks, cracks, cuts, burrs, corrosion, breaks, scoring, chafing, scarring, deformation, dents, thread damage, or any other obvious defects. Make sure that the ports, passages, recesses and sealing grooves are clean and unobstructed. Check all sealing and seating surfaces for damage or corrosion that would affect sealing. Installed Hydrant Shutoff Valve Valve Body (1 or 1A) Check periodically for hot valve condition (excessive internal leakage). Test the valve in accordance with local company policy. Main Piston Seat Check for corrosion and contamination. Can be cleaned and polished with 600-grit emery cloth. Replace if there is heavy corrosion or mechanical damage. Servo Port in Top Flange Check for corrosion and contamination. Can be cleaned and polished with 600-grit emery cloth. Replace if there is heavy corrosion or mechanical damage. Outlet Adapter (2) Sealing Surfaces Check for corrosion and contamination. Can be cleaned and polished with 600-grit emery cloth. Replace if there is heavy corrosion or mechanical damage. Coupler Locking Flange Replace if there is visible heavy corrosion or mechanical damage. GROUND FUELING PRODUCTS GROUP Revision /01/2005 Page 24

27 Table 5. Component Checks (continued) DESCRIPTION (IPL Figure 1 Item Number) Inner Chamber (3) CHECK CRITERIA Piston Bore Check for minor scoring. Can be cleaned and polished with 600-grit emery cloth. Replace if there is heavy scoring. Seal Groove in Piston Bore Replace if there is any damage. Side Port Replace if there is any scoring or damage. Poppet (4) Piston (6) Pedal (7C) Spring (7D) Shaft (7E) Lever (7F) Plunger (5) Packing (11) Packings (12, 22, 25, 25, 26 and 27) Cylinder (13A) Packing (13B) Piston (13C) Seal (14) Molded Seal Replace if there are cuts or other damage. Outside Diameter Check for light scoring. Can be cleaned and polished with 600-grit emery cloth. Replace if the surface coating is worn through to bare metal. Replace if damaged or visible worn. Replace if latching is weak. Replace if bent. Minor corrosion can be cleaned and polished with 600-grit emery cloth. Latch Area Replace if visibly worn. Actuating End and Seat Area Replace if there is visible wear or damage. Replace if there are cuts, deformation or other damage. Replace if there are cuts, swelling, visible wear, deformation or other damage. Check for light scoring or corrosion. Can be cleaned and polished with 600-grit emery cloth. Replace if there is heavy scoring or other damage. Replace if there are cuts, swelling, visible wear, deformation or other damage. Replace if bent. Replace if there is embedded contamination or mechanical damage. GROUND FUELING PRODUCTS GROUP Revision /01/2005 Page 25

28 Table 5. Component Checks (continued) DESCRIPTION (IPL Figure 1 Item Number) Metering Pin (17) Tube (18) CHECK CRITERIA Make sure that all contamination has been removed by cleaning. Replace if there is visible wear on the head end. Check for straightness; replace if bent. Small Diameter Tube End Replace if bent, cracked, or if there is other damage. Packing Grooves Replace if there is any damage. Internal Ball seat and Seal Bore Check for scoring and contamination. Can be cleaned and polished with 600-grit emery cloth. Seat (19) Packing Grooves Replace if damaged. Internal Ball Seat Check for scoring and contamination. Can be cleaned and polished with 600-grit emery cloth. Plunger Bore Replace if scored or contaminated. Packing (28) Plunger (31) Balls (33 and 38) Spring (39) Gasket (45) Thread Seal (46) Tube (48) Always replace if exposed during maintenance. Seal Groove Check for minor scoring. Can be cleaned and polished with 600-grit emery cloth. Replace if there is any damage or major scoring. Replace if there is any corrosion, scratching or pitting. Replace if there is corrosion or deformation. Always replace if removed and the valve has been in service for 3 months or longer. Seal Molding Replace if damaged. Must slip easily into its valve body port. Replace if there is any crushing or other damage. GROUND FUELING PRODUCTS GROUP Revision /01/2005 Page 26

29 TESTING AND ADJUSTMENT 1. General A. Perform all of the tests using Stoddard solvent, jet fuel or equivalent (referred to as solvent herein). B. All of the test equipment and fixtures are to be supplied by user. 2. Valve Test Static A. Test Setup 1) Install the valve in a test setup equivalent to Figure 9. 2) Solvent pressure: 0 to 200 psi (13,8 bar). Flow: 0 to 15 gpm (57 l/m). 3) Air pressure (if required to operate air-servo): 0 to 100 psi (6,9 bar). Figure 9. Leakage Test Setup GROUND FUELING PRODUCTS GROUP Revision /01/2005 Page 27

30 B. Internal Leakage 1) Make sure that the maintenance valve is open. 2) Actuate the servo (7 or 13) open (use air pressure for the air servo). 3) Open the hydrant coupler. 4) Apply 200 psi (13,8 bar) solvent pressure at a flow rate of 15 gpm (57 l/m) maximum. 5) The valve must open (allow solvent to flow until bubbles do not appear in the flow). 6) De-actuate the mechanical servo (7) or vent the air pressure from the air servo (13). 7) The hydrant valve must dose within 30 seconds. 8) The internal leakage must not exceed 30 cc/minute. 6) Remove the solvent pressure. C. External Leakage. 1) Close the hydrant coupler and remove it from the hydrant. 2) Make sure that the maintenance valve is open. 3) Actuate the servo (7 or 13) open (use air pressure for the air servo). 4) Apply 200 psi (13,8 bar) solvent pressure. 5) There must not be any external leakage. 6) Remove the solvent pressure. 7) De-actuate the mechanical servo (7) or vent the air pressure from the air servo (13). 8) Remove the valve from test setup. 3. Valve Test Flow A. Test Setup 1) Install the valve in a test setup equivalent to Figure 10. 2) Solvent pressure: 0 to 120 psi (8,2 bar). Flow: 0 to 1200 gpm (4 500 l/m). GROUND FUELING PRODUCTS GROUP Revision /01/2005 Page 28

31 Figure 10. Flow Test Setup 3) Air pressure (if required to operate air-servo): 0 to 100 psi (6,9 bar). B. Flow Test Procedure 1) Make sure that the maintenance valve is open. 2) De-actuate the mechanical servo (7) or vent the air pressure from the air servo (13). 3) Open the hydrant coupler. 4) Apply 120 psi (8,2 bar) solvent pressure at zero flow. 5) Actuate and de-actuate the servo (7 or 13) open and dosed at least 4 times. 6) Allow the hydrant valve to open and close to remove the air trapped in the inner chamber (3). Use air pressure to actuate the air servo (13). 7) Make sure that valve fully opens and fully closes 8) Actuate the hydrant valve open and set the flow to 1200 gpm (4 500 I/m). 9) Close the maintenance valve. Hydrant valve must close. GROUND FUELING PRODUCTS GROUP Revision /01/2005 Page 29

32 10) Open the maintenance valve and leave it open. The hydrant valve must open. 11) De-actuate the servo (7 or 13). The valve must close in 2 to 5 seconds. 12) Actuate the servo (7 or 13). The valve must open in 5 to 10 seconds. 13) Repeat steps 11 and 12 above at least 3 times. The opening and closing times must be consistent. If the opening and closing times require adjustment, refer to paragraph 5 below. 14) Repeat steps 11 and 12 above after each adjustment. 15) De-actuate the servo (7 or 13). Remove the solvent pressure. 16) Remove the valve from the test setup. 17) Drain the valve (refer to paragraph 4 below). 4. Draining the Valve (Refer to IPL Figure 1) CAUTION: After testing, the valve body and the inner chamber will be full of solvent or test fluid. This fluid must be removed before the valve is transported or stored. A. Turn valve on its side. B. Using a deep 1-inch (25,4 mm) hex socket, remove the maintenance valve (20) from the valve body (1). C. Turn the valve so that the maintenance valve port points straight downward. D. By hand, push the piston (6) fully open and then allow it to close. Repeat this step 5 or 6 times, or until no more solvent comes out of the valve. E. Stand the valve on its inlet flange. CAUTION: If the inner chamber is not correctly aligned, tube (18) could be bent or broken. F. Before installing the maintenance valve in the valve body (1), look into the side port and make sure that the port in the inner chamber (3) is lined up with the side port. Rotate the inner chamber in the valve body as necessary to achieve accurate alignment. The alignment pin (P/N ) may be used to check the alignment. G. Using petrolatum, lubricate the parts and the threads in the valve body (1), the inner chamber (3) and the maintenance valve (20). GROUND FUELING PRODUCTS GROUP Revision /01/2005 Page 30

33 H. Install the maintenance valve (20) in the valve body (1). Torque the maintenance valve to 50 pound-inches (5,7 Nm). 5. Adjusting the Valve A. Remove the servo (refer to MAINTENANCE paragraph 6). B. Remove the adapter and the poppet (refer to MAINTENANCE paragraph 7). C. With a screwdriver in the slot of the needle (17) to prevent rotation, unlock the nut (35). D. Adjust the needle (17) position. Turning the needle inward will reduce the opening and closing times. Turning the needle outward will increase opening and dosing times. E. With a screwdriver in the slot of the needle (17) to prevent rotation, lock the nut (35) securely. Torque the nut to 100 pound-inches (10,5 Nm). F. Re-install the adapter and the poppet (refer to MAINTENANCE paragraph 7). G. Re-install the servo (refer to MAINTENANCE paragraph 6). H. Re-test the valve (refer to paragraphs 1, 2 and 3 above). GROUND FUELING PRODUCTS GROUP Revision /01/2005 Page 31

34 ILLUSTRATED PARTS LIST 1. General This section lists, describes, and illustrates all detail parts required for maintenance support of the Hydrant Shutoff Valve. 2. Scope of Information A. The parts list is arranged in the general order of disassembly. The listing is indentured to show the relationship between each part and its next higher assembly. Item numbers used in the parts list are keyed to the corresponding numbers of the accompanying illustration. B. MODIFICATION CODE The modification code (see Table 1) indicates the parts usage with respect to the end item. When the MODIFICATION CODE column is blank, the part usage is applicable to all versions unless otherwise specified in the DESCRIPTION column. C. Abbreviations ASSY FIG. IPL MOD Assembly. Figure. Illustrated Parts List. Modification. GROUND FUELING PRODUCTS GROUP Revision /01/2005 Page 32

35 IPL Figure 1. Hydrant Shutoff Valve GROUND FUELING PRODUCTS GROUP Revision /01/2005 Page 33

36 FIG. ITEM PART NUMBER DESCRIPTION MOD CODES UNITS PER ASSY F352EM AND F353EM BASELINE HYDRANT SHUTOFF VALVES C BODY, VALVE (Used on F352 only) 1 1 A C BODY, VALVE (Used on F353 only) C BODY, VALVE (Used on F353 only) K C BODY, VALVE (Used on F353 only) L C ADAPTER, OUTLET C ADAPTER, OUTLET N C CHAMBER, INNER C CHAMBER, INNER (Used on F353 only) G C POPPET C PLUNGER C PISTON C SERVO ASSEMBLY (Lanyard operated) (Not used on Mods D and F) 1 7 A CMS C C SCREW, MACHINE 1 CMS C C SCREW, MACHINE (Alternate) 1 7 B CAN C C WASHER, LOCK 1 7 C C C PEDAL 1 7 D F59C1275 C C SPRING, COMPRESSION 1 7 E C C SHAFT 1 7 F F59C1273 C C LEVER 1 7 G CMS C C PIN, SPRING 3 7 H C C BODY, SERVO 1 7 J C C SPRING, TORSION C SPRING, COMPRESSION (Piston) C SPRING, COMPRESSION (Poppet) C SPRING, COMPRESSION (Plunger) BD268 C PACKING, PREFORMED BD248 C PACKING, PREFORMED C SERVO ASSEMBLY D,F 1 13 A C C CYLINDER D,F 1 13 B BD210 C C PACKING, PREFORMED D,F 1 13 C C C PISTON D,F 1 13 D LC032D13MW C C SPRING, COMPRESSION D,F 1 13 E C C RETAINER D,F 1 13 F C C BALL D,F C SEAL 1 GROUND FUELING PRODUCTS GROUP Revision /01/2005 Page 34

37 FIG. ITEM PART NUMBER DESCRIPTION MOD CODES UNITS PER ASSY C SHAFT C CAP, PROTECTIVE C PIN, METERING C TUBE C SEAT C STEM C WASHER (Not shown) C BD117 C PACKING, PREFORMED 1 23 CAN932-3S C PLUG BD116 C PACKING, PREFORMED BD012 C PACKING, PREFORMED BD111 C PACKING, PREFORMED BD013 C PACKING, PREFORMED BD006 C PACKING, PREFORMED C10020 C SCREW, MACHINE C 3 30 N C RING, RETAINING C PLUNGER 1 32 PLGA C PLUG, PIN C BALL DA12045 C SCREW, SOCKET HEAD CAP 8 35 CMS C NUT, HEX 1 36 CAN C WASHER, FLAT C STRAINER A C STRAINER (Used on F353 only) G C BALL C SPRING, COMPRESSION C CLAMP DA08030 C SCREW, SOCKET HEAD CAP 2 42 CMS C PIN, SPRING 1 43 RS450 C RING, RETAINING 1 44 RR850 C RING, RETAINING C GASKET /2 C SEAL, THREAD C SPACER A C SPACER (Used on F353 only) G C TUBE C PLATE, IDENTIFICATION (Not shown) C GUARD, STONE (Used on F352 only) 1 51 UR675 C RETAINER (Used on F352 only) C COVER (Used on F352 only) D 1 GROUND FUELING PRODUCTS GROUP Revision /01/2005 Page 35

38 OVERHAUL PARTS KITS AVAILABLE KIT PART NUMBER DESCRIPTION ITEMS IN KIT (IPL Figure 1) KITF Without Air Servo 11, 12, 14, 22, 24, 25, 26, 27, 28, 30, 33, 39, 45 KITF With Air Servo 11, 12, 13B, 13D, 13F, 14, 22, 24, 25, 26, 27, 28, 30, 33, 39, 45 GROUND FUELING PRODUCTS GROUP Revision /01/2005 Page 36