380GF Series Sexless Coupler : 3-Inch

Transcription

1 380GF Series Sexless Coupler : 3-Inch Installation, Operation and Maintenance Manual N-380GF 3-Inch IOM (R-0/204)

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3 Cla-Val Model 380GF Sexless Coupler Installation, Operation and Maintenance Manual Table of Contents Content Description PAGE # OVERVIEW - INTRODUCTION Exploded View: Complete Assembly 2 OPERATION Installation 3 Connection 3 Operation 3 Part : Basic 3-Inch Sexless Coupling Subassembly 4 MAINTENANCE Exploded View and Parts List 5 Visual Inspection 6 The Basics 6 Look for missing parts 6 7 Replacing Seals 7 REPAIR Remove and Replace Lip Seal (5) 8 Remove and Replace All Internal Seals 8 2 POST-REPAIR TESTING Examination of the Coupling 3 Pressure Testing 3 TROUBLESHOOTING External Leaks 4 Difficulty Connecting Two Coupling Together 4 Difficulty Disconnecting Two Coupling From Each Other 4 Part 2: 3-Inch Hose Barb Adapter Subassembly 5 INTRODUCTION 6 OPERATION Section View and Parts List 7 Installation 8 MAINTENANCE Replacing Seals 8 REPAIR Remove and Replace All Seals 9-20 POST-REPAIR TESTING Examination of the Coupling 2 Pressure Testing 2 TROUBLESHOOTING External Leaks 22 Difficulty Connecting Two Coupling Together 22 Difficulty Disconnecting the Two Coupling From Each Other 22

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5 Installation, Operation and Maintenance Manual The 3-inch 380GF Sexless Coupling is comprised of two main assemblies: () 3-Inch Basic Sexless Coupling Subassembly (2) 3-Inch Adapter For clarity, this Installation, Operation and Maintenance Manual is divided into two parts, one each for the main assemblies noted above. Product Advantages Created for tactical US Army Fuel Systems Interchangeable with similar 3-inch couplings manufactured by other suppliers Sexless configuration is designed to mate with any two couplings, allowing for the connection of hose assemblies, regardless of the end fitting Safety Interlock Design Flat MS Flanges, Hose Barb and NPT Adapter Connections Available Convenient Lift-and-Turn Folding Operating Lever Ball Race Swivel Joint with Low Friction Seal The Cla-Val Model 380GF Sexless Coupling provides a very simple means of connecting two flow conduits together without regard to coupling type. There is no male or female variant, making it possible to connect any two similar couplings. This is especially valuable in environments where visibility is restricted by weather conditions or by darkness. The Model 380GF Sexless Coupling is used whenever there is a need to make quick assembly of system components with speed and in extreme conditions. For more information about the 380GF Sexless Coupling, visit or contact the factory at info@cla-val.com

6 Inch 380GF Sexless Coupler Complete Assembly 90 VALVE ACTUATION A A DUST COVER NOZZLE FLANGE ADAPTER ASSY (MS ) PN C " HOSE BARB ASSY PN F SHOWN SECTION A-A 3-8 NPT THREADED MALE ADAPTER ASSY PN B 380GF ITEM #8 STOCK # PART # DESCRIPTION K C 3" NOZZLE A B 3" MALE NPT B F 3" HOSE BARB ITEM QTY PART # DESCRIPTION MATERIAL 8 SEE TABLE ADAPTER FITTINGS K BALL, LOCKING STAINLESS STEEL A O-RING (3-904) FPM F PLUG, BALL PORT ALUMINUM A CABLE,.0625 DIA STAINLESS STEEL C CABLE CLAMP STEEL C DUST CAP, 3" MACHINED ALUMINUM H BASIC COUPLING SUBASSY, 3" 2

7 OPERATION Installation These instructions cover the installation of the Coupling () and a mating Adapter, like a Hose Barb (8) Fitting Adapter (Adapter) that is usually supplied already installed onto the Coupling. If not installed, follow these instructions. The Adapter (8) is supplied with the seals already installed. If this is not the case, refer to the Maintenance Manual for 3 Sexless Coupling Adapters. Apply a seal lubricant to the seals on the Adapter (8) and to the inside of the Coupling. Insert the Adapter into the receiving end of the Coupling (). Insert the 38 Balls (7) supplied with the Adapter through the threaded port on the opposite side of the Coupling () from the Folding Handle. While inserting the Balls, twist the Adapter to help distribute the Balls in the ball race. When all Balls (7) are inserted, install the Ball Port Plug (5) and O-ring (6) supplied with the Adapter (8) to seal the threaded port and to contain the Balls in the swivel joint. Connection NOTE: THIS SHOULD NOT BE ATTEMPTED UNLESS THE ADAPTER IS INSTALLED INTO THE END OF THE COUPLING TO HOLD THE INTERNAL BALL VALVE IN PLACE. The Sexless Coupling is designed to easily mate to any other Sexless Coupling of the same nominal size conforming to A-A Remove the Dust Cap (2) from the face of the Couplings () if so fitted. Holding two Couplings () so that you can see the connection face of both, align each Large Lug with the larger mating slot/window in the connection face of the mating Coupling. Push the two Couplings together, inserting the Lugs of each into the connection face of each. While pushing them together, rotate one Coupling with respect to the other Coupling in a clockwise direction (as seen from the hose end (Adapter end) of the Coupling). Turn them until a physical stop is contacted, about 30 degrees of rotation. Lift and rotate the Folding Handle of each Coupling to open the ball valve(s). This will also actuate the interlock mechanism of each Coupling. Lifting the Folding Handle is required before rotating the ball valve. The Folding Handle rests in one of two slots in the Body to lock it in place. For the Cla-Val Model 380GF Sexless Coupling, the locking mechanism is a Lock Pin that extends from each Coupling into a recess in the face of the mating Coupler. This locking mechanism prevents the Couplings from being disconnected with the ball valve(s) in the open condition, thereby preventing an unwanted fuel spill. If you cannot turn the Lever/Handle of the Coupling, check to see if the Couplings are completely rotated together. Operation NOTE: THIS SHOULD NOT BE ATTEMPTED UNLESS THE ADAPTER IS INSTALLED INTO THE END OF THE COUPLING TO HOLD THE INTERNAL BALL VALVE IN PLACE. Once both ball valves in the mated Couplings are opened, flow can be established through the Couplings. It is recommended that the flow of fuel through the Couplings be stopped before closing the ball valve features (if so fitted). If the ball valves are to be closed during flow, it is recommended (but not required) that the ball valve in the upstream Coupling be closed first. Once both ball valves have been closed, the locking mechanisms in both Couplings should be disengaged, allowing for the rotation of one Coupling with respect to the other. To disconnect, rotate the Couplings until a physical stop is contacted, and pull them apart. In some cases, there will hydraulic suction keeping the Couplings together, but this will be easily overcome by gently pulling the Couplings apart after they have been fully rotated counterclockwise. 3

8 380GF MAINTENANCE MANUAL Part : Basic 3-Inch Sexless Coupling Subassembly Reference Drawing #

9 Exploded View and Parts List: Parts List: ITEM QTY PART NO H D G 0072A B 00738F A H G F E J 0074G 66253G F D F D E K D F F DESCRIPTION BODY BUMPER STEM, LOWER O-RING LIP SEAL O-RING SEAL, BALL BALL, SEXLESS COUPLING LUG, SMALL LUG, LARGE LOCK PIN STEM, UPPER O-RING BALL RETAINER, BALL SPRING, COMPRESSION CLEVIS PIN, GROOVED OPERATING LEVER FOLDING HANDLE SCREW, FLAT HD W/SOCKET RETAINING RING SOC. HD. CAP SCREW SPRING, TORSION MATERIAL ALUMINUM NITRILE STAINLESS STEEL BUNA-N NITRILE BUNA-N PTFE TEFLON ALUMINUM STAINLESS STEEL STAINLESS STEEL STAINLESS STEEL STAINLESS STEEL BUNA-N STAINLESS STEEL ALUMINUM STAINLESS STEEL STAINLESS STEEL ALUMINUM ALUMINUM STAINLESS STEEL COPPER STAINLESS STEEL STAINLESS STEEL 5

10 Basic 3-Inch Sexless Coupling Subassembly MAINTENANCE Visual Inspection The Basics: NOTE: THIS SECTION APPLIES TO COUPLINGS ASSEMBLED WITH ADAPTERS. A quick visual inspection of the Coupling can be a very effective way of preventing dangerous fuel spillage. Each Coupling should be inspected at least every 3 months (every quarter) to verify that the Coupling is in operating order. In addition, each Coupling of a packaged fuel system should be inspected prior to each deployment. When inspecting the Coupling, first inspect the connection face of the Coupling. Verify that the Lip Seal (5) is in place. Remove the Lip Seal and inspect it for any cracks or scratches on both sides. If any damage to the Lip Seal is found, replace it with a new one. When installing the Lip Seal into the Body (), start on one side and make sure the Lip Seal fits under the lip of the Body that retains the Lip Seal in place. Then push the rest of the Lip Seal down into the groove. The heel of the Lip Seal (5) should be flush with the face of the Body and the lip of the Lip Seal will stand above the face, ready to contact the Lip Seal in the mating Coupling. Verify that BOTH the Large Lug (0) and Small Lug (9) are in place and firmly affixed to the Coupling. Bent, damaged or loose Lugs may interfere with a good connection and may result in a fuel spill. Though the Lugs are made of Stainless Steel (and protected by a Dust Cap when disconnected), they can become damaged through rough handling. If you find cracks of missing pieces, replace the Lugs. Visually inspect the gripping lip of both Lugs. The gripping lip should be flat and without burrs or raised sharp edges. (Note that each Lug has a chamfered leading edge to aid in connection to the mating Coupling that should not be considered as damage.) If such damage is found, it may result in a weak connection to the mating Coupling. Replace the Lugs when such damage is found. Look for physical damage that might occur from impact from other items or surfaces. Significant scrapes or gouges on the exterior of the Coupling can result in dangerous sharp edges and in exterior leakage when pressurized and flowing and also can result in a personal hazard. Look for missing parts: NOTE: THIS SECTION APPLIES TO COUPLINGS ASSEMBLED WITH ADAPTERS. Each Coupling should have a Dust Cap connected to it by a length of Stainless Steel Cable. Inspect the Cable for frayed or sharp pieces. Inspect the Dust Cap for cracked or missing pieces. Note that each Dust Cap has a spare Lip Seal (5) installed that can be removed and installed into the connection face of the Coupling. The Dust Cap can continue to be used after the spare Lip Seal is removed. Don t forget to obtain a replacement Lip Seal to install in the Dust Cap. The connection face of each Coupling should have two Lugs, a Lip Seal (5), and a spring loaded Ball (4) held in place by a round Ball Retainer (5). If any of these are missing, do not use the Coupling until they are replaced. Each Coupling should have a rubber Bumper (2) around the large end of the Coupling Body (). Though the Coupling can be safely used without the Bumper, the Bumper should be in place to protect the Coupling from impact with other surfaces. Inspect the Bumper for cracks or missing pieces. Replace as necessary. 6

11 Basic 3-Inch Sexless Coupling Subassembly MAINTENANCE Look for missing parts: (continued) The spring loaded Folding Handle (9) is attached to the Operating Lever (8). The Folding Handle should be free to be lifted against the spring force and should fold and store freely. Inspect the Folding Handle for scratches and gouges that would result in sharp edges. Verify that the Torsion Spring (23) is in place and functioning correctly. The Torsion Spring must be functioning correctly to lock the ball valve in the fully open and fully closed positions. Verify that the two Socket Head Screws (20) that hold the Operating Lever onto the Stem (2) of the Coupling are in place and are screwed in tightly. Verify that the Ball Port Plug and O-ring are in place in the threaded port of the Body (). The swivel joint between the Body and the Adapter contains 38 Balls and are held in place by this Ball Port Plug. If the Ball Port Plug or O-ring are missing, do not use the Coupling until they are replaced and you are sure that all 38 Balls are in the swivel joint. When not connected to another Coupling, the Folding Handle (9) of the Coupling can be lifted and rotated from the OPEN position to the CLOSED position. Verify that the Lock Pin () extends from the connection face when the Folding Handle is in the open position and retracts to flush or sub-flush with the connection face when in the closed position. REPLACING SEALS: The rubber and Teflon seals within the Coupling should be replaced whenever they are found to be defective. It is recommended that these items be replaced every 24 months, although service life of these components can be much longer depending on the application. The following is a list of these items within each Coupling. ITEM QTY. PART NO. 0072A B 00738F D A 0074G DESCRIPTION O-RING LIP SEAL O-RING BUMPER SEAL, BALL O-RING All these items are sold as a Repair Kit, Cla-Val part number H. Follow the instructions in REPAIR section to remove and replace these seals. 7

12 Basic 3-Inch Sexless Coupling Subassembly REPAIR Remove and Replace Lip Seal (5): You will need: A Silicone-based o-ring lubricant that is specifically formulated for use with rubber O-Rings. Removal: Grab exposed lip of Lip Seal (5) and pull it free from the mating groove in the connection face of the Body (). Re-assembly: Lubricate the new Lip Seal (5). Twist the Lip Seal (5) slightly so that you can insert the inner lip down into the groove in the connection face of the Body (). Once that portion of the Lip Seal is down into the groove, push the rest of the Lip Seal into the groove all the way around. When correctly installed, the Lip Seal outer lip will stand out from the connection face, but the heel of the Lip Seal will be flush or close to flush with the connection face. Remove and Replace All Internal Seals (Ball Seal and mating O-ring, and O-rings on Upper and Lower Stems): You will need: A pair of pliers. 3/32 hex key (Allen wrench). An O-ring Pick or similar tool. An O-Ring lubricant that is specifically formulated for use with rubber O-Rings. Liquid thread locking compound (Loctite 242 Medium Strength or equivalent) Torque wrench to torque hex key (Allen wrench) to 9 in. lbs. Removal: NOTE: THE ADAPTER MUST BE DISASSEMBLED FROM THE COUPLING TO GET TO THESE PARTS. See the Adapter Maintenance Manual for instructions to remove the Adapter. When disassembled, the Folding Handle (9) of the Coupling (and the internal ball valve) in the OPEN position so that the Ball (8) is retained within the Body (). To remove the Ball (8) from the Body (), rotate the Folding Handle (9) to the CLOSED position, being careful to prevent the Ball from falling out of the Coupling. When fully rotated, the Ball will be free to come out of the Body. Remove the Ball and protect the surface of the Ball from any dings or scratches. Carefully remove the Ball Seal (7) from within the Body (). Remove O-ring (6) from within the groove inside the Body. Do not scratch any of the internal sealing surfaces. Inspect the inside of the Body () for any damage or debris. Check the swivel joint ball groove for damage or burrs. There may be some dents in the ball groove (sometimes caused when the Coupling is dropped) but that does not mean that the Body needs to be replaced. 8

13 Basic 3-Inch Sexless Coupling Subassembly REPAIR (continued) Remove and Replace All Internal Seals The Upper Stem (2) and its O-ring (3) is captured in a hole in the top of the Body () by the Operating Lever (8) and Folding Handle (9) affixed to the top of it. To remove the Upper Stem, remove the two Socket Head Screws (20) that attach the Operating Lever to the Upper Stem. Remove the Operating Lever with the Folding Handle attached. Push the Upper Stem down into the Body until it falls free. Remove the Upper Stem from within the Body and remove the O-ring from the Upper Stem. The Lower Stem (3) is only held in place by the friction of the O-ring (4) assembled on it. Use a pair of pliers to grip the blade (or key) on the top of the Lower Stem and pull it up and out of the hole in the Body. Then remove the O-ring from the Lower Stem. Remove the Lock Pin () from the hole in the connection face of the Body so that it does not fall out and become lost. There are no seals directly associated with the Lock Pin. Re-assembly: Clean the interior of the Body (). Lubricate all O-rings. Lubricate the top and bottom holes in the Body () for the Upper Stem (2) and Lower Stem (3). NOTE: Look at the Lower Stem (3) and the Lock Pin (). They have slots and teeth that work together to extend and retract the Lock Pin as the Lower Stem rotates. These features will come into play during assembly as explained in later steps in this section. Install O-ring (3) into the groove on the Upper Stem (2). Press the Upper Stem (2) into the top hole in the Body () from the inside of the Body. Place a small amount of thread locking compound on one side of each of the Socket Head Screws (20) when in the mating holes of the Upper Stem. Line up the two holes in the Operating Lever (8) with the threaded holes in the Upper Stem and install the two Socket Head Screws. Torque to 9 lbs. When finished, turn the Upper Stem and the Operating Lever to the CLOSED position. Install O-ring (4) into the groove on the Lower Stem (3). The Lower Stem (3) must be installed and timed with the Lock Pin (). Align the Lower Stem inside the Body () as shown in the images below. Note that the blade (or key) on the top of the Lower Stem (3) is aligned across the Body (), NOT in line with the centerline of the Body. Also note that the slots in the Lower Stem (3) must be on the side of the Lower Stem closer to the connection face of the Body. 9

14 Basic 3-Inch Sexless Coupling Subassembly REPAIR Reassembly (continued) Push the Lower Stem (3) down into the Body () until it stops, as shown below. Turn the Lower Stem (3) clockwise approximately 45 degrees so that it looks like the image below. 0

15 Basic 3-Inch Sexless Coupling Subassembly REPAIR Reassembly (continued) Align the Lock Pin () with the mating hole in the connection face of the Body (). The teeth of the Lock Pin should be located as shown below so that they will engage the slots in the Lower Stem (3). Push the Lock Pin () into the Body () until it stops. As you continue to push, gently rotate the Lower Stem (3) counterclockwise. The Lock Pin will engage the Lower Stem as you turn it, as below.

16 Basic 3-Inch Sexless Coupling Subassembly REPAIR Reassembly (continued) When the Lower Stem (3) has been rotated so that the blade (or key) is in line with (parallel to) the centerline of the Body (), as shown below, then the Lock Pin () will be retracted and flush with the connection face of the Body. Install O-ring (6) into groove inside the Body (). Install the Ball Seal (7) into the Body () covering the O-ring (6). Make sure that both the Upper Stem (2) and the Lower Stem (3) are positioned so that the blade (or key) of each is parallel with the centerline of the Body () so that the Ball (8) can be installed with the slots in the top and bottom of the Ball engage the blades (or keys). Note that the Ball (8) has slots in top and bottom. The top slot is the wider of the two and must engage the Upper Stem (2). The bottom slot is smaller and must engage the Lower Stem (3). Carefully insert the Ball (8) into the Body (). The slots and blades (or keys) must align to do this. Once the Ball (8) is in place, rotate the Folding Handle (9) to the OPEN position. This will capture the Ball so that it cannot fall out. Proceed with installing the Adapter into the open end of the Coupling, onto the Ball (8). 2

17 Basic 3-Inch Sexless Coupling Subassembly POST-REPAIR TESTING: Examination of the Coupling: NOTE: THIS SECTION APPLIES TO COUPLINGS ASSEMBLED WITH ADAPTERS. After every form of service other than simple visual inspection, the Coupling must be evaluated and tested prior to being put back into service. When disconnected, verify that each coupling half opens and closes without restriction of interference. Verify that the Lip Seal (5) is in place. Verify that the Lock Pin () extends and retracts when the ball valve is opened and closed. Pressure Testing: Note: DO NOT TEST WITH WATER. All pressure tests should be performed using jet fuel or a suitable substitute such as Mil-C-7024 Type II calibration fluid. Wear appropriate safety gear. Be prepared to catch or contain any fluid that might leak from the Coupling during testing. Couplings must be tested separately and in pairs, so if you are just testing one Coupling, you will need another Coupling to complete testing. Make a suitable connection to whatever Adapter is fitted to the Coupling to a test fluid pressure source. With the Coupling NOT connected to another Coupling, purge the Coupling of all air so that it is completely filled with test fluid. With the Coupling in the CLOSED position, pressurize the inlet of the Coupling to 4 to 6 psig. Hold this pressure for one minute. There should be no sign of leakage or damage. Pressurize the Coupling to 00 psig. Hold this pressure for one minute. There should be no sign of leakage or damage. Pressurize the Coupling to 300 psig. Hold this pressure for one minute. There should be no sign of leakage or damage. Relieve all pressure. Connect the Coupling to another Coupling. Open the ball valves of both and purge the Couplings of all air. Attempt to disconnect the Couplings from each other. This should not be possible if one (or both) Coupling is in the OPEN position. With both Couplings in the OPEN position, pressurize the Couplings to 4 to 6 psig. Hold this pressure for one minute. There should be no sign of leakage or damage. Pressurize the Coupling to 300 psig. Hold this pressure for one minute. There should be no sign of leakage or damage. Disconnect the Couplings from the pressure source. Close both Couplings and disconnect the two Couplings from each other. Inspect the connection face to verify that the Lip Seal (5) is in place and not damaged or dislodged by the pressure tests. 3

18 Basic 3-Inch Sexless Coupling Subassembly TROUBLESHOOTING: External Leaks: If an external leak is found when two Couplings are connected together, it is likely attributable to one of the Lip Seals (5). Remove one or both Lip Seals and inspect them for cuts, scratches or missing material. Replace with new if damage is found. Note: Spare Lip Seals are installed inside the Dust Cap. Leaks around the Upper Stem (2) and Operating Lever (8) likely mean that the O-ring (3) around the Upper Stem needs to be replaced. Leaks around the swivel joint between the Body () and the Adapter likely mean that the O-ring around the Adapter needs to be replaced. Other external leaks coming through the external metal parts are likely due to external damage to these parts from impacts or other abuse. Remove the Coupling immediately and contact Cla-Val for assistance in replacing metal parts. Difficulty connecting two Couplings together: Visually inspect the Large Lug (0) and Small Lug (9) on the connection face of each Coupling. If one is bent or has heavy damage, it should be replaced. Contact Cla-Val for assistance in replacing metal parts. If you find that one of the Lugs is loose, tighten the Socket Head Cap Screws (22) that hold the Lugs in place. You can gain access to the screws and lugs by removing the Bumper (2) from the Body. Difficulty disconnecting two Couplings from each other: If both ball valves are closed, but you cannot rotate the Couplings to disconnect them, it is likely that one of the Lock Pins () is not retracting like it should when the Lower Stem rotates to the CLOSED position. You will have to disassembly the Coupling to get at the Lower Stem (3). Remove the Lower Stem and inspect the slots that interface with the Lock Pin for damage. Use a pick or other suitable tool to reach into the hole for the Lower Stem to try to move the Lock Pin. If you can rotate the Couplings, but not far enough to disconnect, there may be some foreign material between the Couplings that is interfering with the rotation. You can try to dislodge the foreign material with impacts against a firm object. You may have to remove the Bumper from one or both Couplings and remove the Socket Head Cap Screws (22) that hold the Large Lug (0) and Small Lug (9) in place; then try to rotate the Couplings to disconnect them. You may have to remove the Socket Head Cap Screws from both Couplings to get the Couplings to come apart. 4

19 380GF MAINTENANCE MANUAL Part 2: 3-Inch Hose Barb Adapter Subassembly Reference Drawing #

20 Part 2: 3-Inch Hose Barb Adapter Subassembly INTRODUCTION This Maintenance Manual covers the OPERATION, MAINTENANCE and REPAIR of Cla-Val Model 380GF 3-inch Hose Barb Adapter, referred from here on as just Adapter. However, you can use this Maintenance Manual for all such optional Adapters available for the 3-inch 380GF Sexless Coupling. Those Adapters are shown below. Minor differences exist between these Adapters, but the maintenance issues described in this document apply to all such Adapters. The OPERATION section contains information for the installation and use of the Coupling. The MAINTENANCE section contains information for the regular inspection and service. The REPAIR section contains information on how to disassemble and re-assemble the Coupling. The TROUBLESHOOTING section contains helpful hints for diagnosing problems. 6

21 Part 2: 3-Inch Hose Barb Adapter Subassembly OPERATION Sectional View and Parts List: Parts List: ITEM * QTY. 2 PART NO C 086G F D E K DESCRIPTION FITTING, 3 HOSE BARB* O-RING RACE RING WAVE SPRING WASHER, PLAIN FLAT BALL GUIDE MATERIAL ALUMINUM FLUOROSILICONE STAINLESS STEEL STAINLESS STEEL ALUMINUM TEFLON *All parts listed EXCEPT item are common to all Adapters for the 3 380GF Sexless Coupling. Additional adapters include: Nozzle fitting F and Flange O-Ring 00785G Male NPT G 7

22 Part 2: 3-Inch Hose Barb Adapter Subassembly OPERATION Installation These instructions cover the installation of the Adapter into the Basic 3 Sexless Coupling. The Adapter shown in this document is a 3 Hose Barb Fitting, but all such Adapters are fitted to the Basic 3 Sexless Coupling in the same way. Stand the Adapter ()on a horizontal surface with the swivel joint and O-ring end up, with the Wave Spring (4), Washer (5) and the Ball Guide (6) inside. Place the open end of the 3 Basic Sexless Coupling Body (with the Ball Valve inside) down onto and over the Adapter. You will have to lift the Folding Handle (in the OPEN position) to get this started. Pick up the assembly making sure that you keep the Adapter pushed into the Body. This keeps the Wave Spring (4), Washer (5) and the Ball Guide (6) in place. Turn the assembly horizontal with the threaded port in the Body (for the swivel joint Balls) facing up so that you can insert the 38 of ¼ Stainless Steel Balls that hold the joint together. Looking down into the port, push the Adapter into the Body against the spring force from the Wave Spring (4). Push it is far enough to align the ball race of the Adapter with the port in the Body and start inserting the 38 Balls into the swivel joint. Twist the Adapter to aid in distributing the Balls in the ball race. After a few Balls are installed, you will no longer need to push the parts together because the Balls will hold the assembly together. When all 38 Balls are inserted, apply a small amount of thread locking compound to the threads of the Ball Port Plug (supplied with each Sexless Coupling). Confirm that there is an O-ring under the head of the Ball Port Plug, and install the Ball Port Plug into the threaded port of the Body to retain the Balls. REPLACING SEALS: The rubber and Teflon seals of the Adapter should be replaced whenever they are found to be defective. It is recommended that these items be replaced every 24 months, although service life of these components can be much longer depending on the application. The following is a list of these items on or in the Adapter. ITEM 2 6 QTY. PART NO. 086G K DESCRIPTION O-RING BALL GUIDE All these items are sold within a Repair Kit, Cla-Val part number H. Follow the instructions in section 4.0 REPAIR below to remove and replace these seals. 8

23 Part 2: 3-Inch Hose Barb Adapter Subassembly REPAIR Remove and Replace All Seals (Swivel O-ring & Ball Guide): You will need: A cup or other shallow container to catch swivel joint Balls. An O-ring Pick or similar tool. An O-Ring lubricant that is specifically formulated for use with rubber O-Rings. Liquid thread locking compound (Loctite 242 Medium Strength or equivalent) Removal: NOTE: The swivel joint must be disassembled to get to these parts. Note that there is an internal spring force that is being opposed by the Balls in the ball races in the Body and the Adapter. (This is also the case for any other mating components taking the place of the Adapter.) When all Balls have been removed from the swivel joint, except for the last one, then getting the last ball out will result in the release of the spring force, causing the Adapter to jump away from the Body. This jump is minor and is easily controlled by one person. Start with the Folding Handle of the Coupling (and the internal ball valve) in the OPEN position. Remove the Ball Port Plug from the port located on the opposite side of the Coupling from the Folding Handle. Remember that the Balls in the swivel joint will be free to fall out of this port, so be ready to catch the Balls in a cup. Remember that there is an internal spring force trying to push the Adapter out of the Body. Rotate the Adapter with respect to the Body to bring all Balls to the port, one-by-one. You will have to look into the port to watch for the last Ball to become available for removal. When the last Ball can be seen in the port, turn over the Coupling so that the port is facing down, then push the Adapter in (against the spring force) to release the last Ball so that it can fall free. Remove the Adapter (and related components) from within the Body. Note that the Ball Guide (6), Washer (5) and the Wave Spring (4) will be free and may fall out. Remove them as well. With the Coupling is in the OPEN position, the Ball Valve will be held in place in the Body. Remove the O-ring (5) from the large diameter of the Adapter. Re-assembly: Clean the interior of the Body. Lubricate all O-rings. Install the O-ring (5) onto the Adapter. Make sure that the O-ring (5) is in the correct groove and is NOT in the ball groove of the Adapter. Place the Wave Spring (4), Washer (5) and Ball Guide (6), in that order, into the large end of the Adapter. The flat surface of the Ball Guide should be against the Washer (5). Stand the Adapter on a horizontal surface with the swivel joint end up, with the Wave Spring (4), Washer (5) and Ball Guide (6) inside. Place the open end of the Coupling (with the Ball Valve inside) down onto and over the Adapter. You will have to lift the Folding Handle to get this started. 9

24 Part 2: 3-Inch Hose Barb Adapter Subassembly REPAIR 4. Remove and Replace All Seals (Swivel O-ring & Ball Guide): Pick up the assembly making sure that you keep the Adapter pushed into the Coupling. This keeps the Ball Guide (6), Washer (5) and Wave Spring (4) in place. Turn the assembly horizontal with the port in the Coupling Body for the swivel joint Balls facing up so that you can insert the Balls. Looking down into the port, push the Adapter into the Body against the spring force from the Wave Spring (4). Push it is far enough to align the ball race of the Adapter with the port in the Body and start inserting the Balls into the swivel joint. After a few Balls are installed, you will no longer need to push the parts together because the Balls will hold the assembly together. Turn the Adapter as you insert all the Balls into the port. When all 38 Balls are inserted, apply a small amount of thread locking compound to the threads of the Ball Port Plug and install the Ball Port Plug into the threaded port of the Body to retain the Balls. 20

25 Part 2: 3-Inch Hose Barb Adapter Subassembly POST-REPAIR TESTING: Examination of the Coupling: After every form of service other than simple visual inspection, the Coupling must be evaluated and tested prior to being put back into service. When disconnected, verify that each coupling half opens and closes without restriction of interference. Verify that the Lip Seal is in place. Verify that the Lock Pin extends and retracts when the ball valve is opened and closed. Pressure Testing: All pressure tests should be performed using jet fuel or a suitable substitute such as Mil-C-7024 Type II calibration fluid. DO NOT TEST WITH WATER. Wear appropriate safety gear. Be prepared to catch or contain any fluid that might leak from the Coupling during testing. Couplings must be tested separately and in pairs, so if you are just testing one Coupling, you will need another Coupling to complete testing. Connect a test fitting to the Adapter of the Coupling securely to contain pressure. Attach the Coupling to a suitable pressure source. With the Coupling NOT connected to another Coupling, purge the Coupling of all air so that it is completely filled with test fluid. With the Coupling in the CLOSED position, pressurize the inlet (Adapter) of the Coupling to 4 to 6 psig. Hold this pressure for one minute. There should be no sign of leakage or damage. Pressurize the Coupling to 00 psig. Hold this pressure for one minute. There should be no sign of leakage or damage. Pressurize the Coupling to 300 psig. Hold this pressure for one minute. There should be no sign of leakage or damage. Relieve all pressure. Connect the Coupling to another Coupling. Open the ball valves of both and purge the Couplings of all air. Attempt to disconnect the Couplings from each other. This should not be possible if one (or both) Coupling is in the OPEN position. With both Couplings in the OPEN position, pressurize the Couplings to 4 to 6 psig. Hold this pressure for one minute. There should be no sign of leakage or damage. Pressurize the Coupling to 300 psig. Hold this pressure for one minute. There should be no sign of leakage or damage. Disconnect the Couplings from the pressure source. Close both Couplings and disconnect the two Couplings from each other. Inspect the connection face to verify that the Lip Seal is in place and not damaged or dislodged by the pressure tests. 2

26 Part 2: 3-Inch Hose Barb Adapter Subassembly TROUBLESHOOTING: External Leaks: If an external leak is found when two Couplings are connected together, it is likely attributable to one of the Lip Seals. Remove one or both Lip Seals and inspect them for cuts, scratches or missing material. Replace with new if damage is found. Leaks around the Upper Stem and Operating Lever likely mean that the O-ring around the Upper Stem needs to be replaced. Leaks around the swivel joint between the Body and the Hose Barb Fitting likely mean that the O-ring (2) around the Adapter needs to be replaced. Other external leaks coming through the external metal parts are likely due to external damage to these parts from impacts or other abuse. Remove the Coupling immediately and contact Cla-Val for assistance in replacing metal parts. Difficulty connecting two Couplings together: Visually inspect the Large Lug and Small Lug on the connection face of each Coupling. If one is bent or has heavy damage, it should be replaced. Contact Cla-Val for assistance in replacing metal parts. If you find that one of the Lugs is loose, tighten the Socket Head Cap Screws that hold the Lugs in place. Remove the Bumper from the Body to gain access to the lugs and screws. Difficulty disconnecting two Couplings from each other: If both ball valves are closed, but you cannot rotate the Couplings to disconnect them, it is likely that one of the Lock Pins is not retracting like it should when the Lower Stem rotates to the CLOSED position. To gain access to the Lower Stem, disassemble the Coupling. Remove the Lower Stem and inspect the slots that interface with the Lock Pin for damage. Use a pick or other suitable tool to reach into the hole for the Lower Stem to try to move the Lock Pin. If you can rotate the Couplings, but not far enough to disconnect, there may be some foreign material between the Couplings that is interfering with the rotation. You can try to dislodge the foreign material with impacts against a firm object. The Bumper and Socket Head Cap Screws that hold the Large and Small Lugs in place on one or both couplings may need to be removed. Once that is done, try rotating the couplings to disconnect. 22

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28 Global Capabilities. Local Expertise. Cla-Val manufactures superior quality automatic control valves in production facilities located around the world. These facilities, coupled with sales offices and distribution centers in the United States, Canada, Switzerland, United Kingdom and France, enable Cla-Val to provide worldclass product support to our customers wherever they are, whenever they need it. Global Headquarters CLA-VAL P.O.Box 325 Newport Beach, CA Phone: (949) Toll Free: (800) Fax: (949) In addition to our state-of-the-art manufacturing and foundry facilities in the US, Cla-Val Canada also supports North American customers in a diverse array of industries with superior quality products and services and is one of the continent s leading high volume OEM suppliers. Our manufacturing operation in Lausanne, Switzerland, backed by an expert team of engineers and customer service professionals, provides outstanding product and technical support to customers throughout Europe and the Middle East. Cla-Val UK Ltd. serves the United Kingdom and South Africa with an unparalleled level of customer service and technical expertise. Primary markets include waterworks, fire protection, aviation fueling and industrial processing facilities. Cla-Val France, with offices located in Lyon, is one of the leading suppliers of automatic control valves in France. Serving diverse markets ranging from aviation fuel truck manufacturing to water utility companies, Cla-Val France brings a unique combination of industry experience, technical expertise and product know-how to customers in the French marketplace. A World of Applications In addition to serving the aviation ground fueling industry, Cla-Val has provided the finest quality automatic control valves to the following markets for more than seventy-five years. Waterworks Distribution: Cla-Val is the leading provider of automatic control valves and related products for the waterworks industry in the US and around the world. Our extensive product line includes pressure reducing valves, pressure relief valves, water savings products, remote and electronic control valves and a myriad of other products to ensure water system efficiency and reliable operations. Industrial/Wastewater: Our extremely versatile automatic control valve, so prevalent in the waterworks industry, can also be customized to meet the demands of virtually any industrial fluid handling or wastewater application. complete solutions provided by Cla-Val Worldwide Locations CLA-VAL EUROPE Switzerland Phone: Fax: CLA-VAL UK Phone: Fax: CLA-VAL FRANCE Phone: Fax: CLA-VAL CANADA Phone: Fax: CLA-VAL PACIFIC Phone: Fax: Fire Protection: Cla-Val fire protection products are specified by engineers and architects around the world, performing with reliability and precision in fire suppression systems on offshore oil platforms, industrial facilities and in high-rise buildings. Marine: Cla-Val s marine products are designed to meet the exacting requirements of military and commercial shipboard applications including fire protection systems, aircraft fueling and seawater service. Their rugged construction and top quality materials help to ensure long life, minimal maintenance and precision performance. N-380GF_3-Inch_IOM (R-0/204)