WATER SUMP CONTROL VALVE F532B
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 1.0 11/01/2004 The total number of pages in this technical document is 16 consisting of the following: Title, A, 1 14 TABLE OF CONTENTS SUBJECT PAGE Introduction 1 Description and Operation 1 Fault Isolation 4 Disassembly 6 Cleaning 7 Inspection 8 Assembly 9 Testing 11 Illustrated Parts List 12
1. General INTRODUCTION This manual provides component maintenance shop instructions for the Water Sump Control 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 Water Sump Control Valve (valve) (see Figures 1 and 2) provides the means of detecting free water accumulation in filter/separators, storage tanks and other refueling system components. The major functional components of the valve are the float, the valve, the sump and the plunger assembly. 2. Operation A. Negligible Free Water Accumulation When the accumulated free water in the sump is negligible, the specific gravity of the float is sufficient to keep it from floating, and the refueling system operates normally. B. Excessive Free Water Accumulation As free water accumulates, its higher specific gravity causes the float to move upward. When the free water accumulation is sufficient, float movement actuates its normally open valve closes and opens a path for the system reference pressure to vent. When this occurs, the refueling system shuts down due to the lack of reference pressure to its control valves.
C. Refueling System Restart When the refueling system has been shut down due to excessive free water accumulation in the valve sump, operator action is required to drain the water. When the water has drained, the float will sink, the vent valve will close, and normal operation will resume. D. Pre-Check Plunger The pre-check plunger provides the means to verify proper operation of the valve. When the plunger is pushed, it manually lifts the float and operates the valve, causing system reference pressure to vent. An audible sound is produced when the system reference pressure vents. The pre-check plunger should be used periodically, in accordance with the operator s established operating procedures. E. Reference Pressure Source The valve can operate with reference air or fuel pressure. Reference air can be vented to the atmosphere. Reference fuel pressure must be vented to a low pressure purge tank. 3. Leading Particulars (Refer to Table 1) Table 1. Leading Particulars Service Automotive and Aviation Fuels and Water Operating Pressure Maximum Working 200 psi (1 380 kpa) Through Valve 85 psi (590 kpa) Fluid Temperature 35 to 135 F ( 37 to 57 C) Ambient Temperature 65 to 160 F ( 54 to 71 C) Weight (approximate) 15 pounds (6,8 kg) (Specific gravity: 0.83 maximum)
FAULT ISOLATION 1. General Refer to Table 2 for fault isolation information. Locate suspected faulty component and take appropriate remedial action. Table 2. Fault Isolation FAULT POSSIBLE CAUSE CORRECTIVE ACTION Valve will not close Pivot (15, IPL Figure 1) improperly adjusted Seat in valve body (12) excessively worn or damaged due to contamination Table 2. Fault Isolation Adjust the pivot (refer to ASSEMBLY section, paragraph 3F). Replace the valve body. FAULT POSSIBLE CAUSE CORRECTIVE ACTION Valve will not close Leakage from the vent port Weight of float assembly (items 16 through 19) is incorrect Reference pressure inlet and outlines switched Seat of poppet (6) excessively worn or damaged due to contamination Seat in valve body (12) excessively worn or damaged due to contamination Check and correct the float weight (refer to ASSEMBLY paragraph 3F). Reverse the lines. Replace the poppet. Replace the valve body.
Fuel to air leakage contamination Pivot (15) improperly adjusted Weight of float assembly (items 16 through 19) is incorrect Damaged quad rings (9) due to contamination Adjust the pivot (refer to ASSEMBLY section, paragraph 3F). Check and correct the float weight (refer to ASSEMBLY paragraph 3B). Replace the quad rings. DISASSEMBLY NOTE: Prior to disassembly, the vessel in which the water sump control valve is installed must be drained in accordance with the applicable instructions, and the water sump control valve must be disconnected and removed from the vessel. 1. Seal Replacement Parts Kits Refer to the ILLUSTRATED PARTS LIST section for the Replacement Parts Kit information. 2. Disassembling the Water Sump Control Valve (Refer to IPL Figure 1) A. Remove the packing (20) from the packing groove of the sump (21). B. Remove the screws (7), the washers (8), the cap (1), the spring (5) and the poppet (6) from the valve body (12). Remove the packings (2 and 4) and the packing cap (3) from the valve body. C. Remove the screws (10), the washers (11) and gently pull the valve body (12) away from the sump (21). Using a suitable small diameter tool (a straightened large paper clip works well), push out the pin (16), and remove the valve body and associated parts. D. Remove the packing (13) and the pivot (15) from the valve body. CAUTION: BE CAREFUL NOT TO CHANGE THE SETTING OF THE PIVOT (15). IT IS SET AT THE FACTORY TO THE DIMENSION SHOWN IN FIGURE 2. E. Remove the rod (14) from the valve body (12). Remove the packings (9) from the rod. F. Remove the float from the sump. Remove the plug (17) and the packing (18) from the float. G. If there has been leakage from the plunger assembly, remove the plug (22.1) from the sump (21). Remove the ring (22.5) from the plunger (22.2). Remove the plunger (22.2), the backup ring (22.3), and the packings (22.4) from the plug
CLEANING 1. Cleaning Materials 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.
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) DESCRIPTION Table 5. Component Checks (IPL Figure 1 Item Number) General Poppet (6) Rod (14) 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. The inside and outside diameters must be free of scratches. The air passages must not be obstructed (free air flow is critically important). The seating faces must be free of scratches.
ASSEMBLY 1. Overhaul and Seal Replacement Parts Kits Refer to the ILLUSTRATED PARTS LIST section for the recommended seal and overhaul replacement parts kit information. 2. Assembly 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 Grease, Silicone 33 Dow Corning (commercially available) 3. Assembling the Water Sump Control Valve (Refer to IPL Figure 1) A. Lubrication Prior to assembly, lightly lubricate all of the packings, seals and screw threads with silicone grease (#33). B. Assembling the Float Assembly Fill the float (19) with water to a weight of 4.15 (±0.05) pounds (1,87 to 1,90 kg) (including the packing (18) and the plug (17). Tighten the plug securely. CAUTION: DO NOT STRETCH THE PACKING CAP (3). BE CAREFUL NOT TO CREASE THE PACKING CAP DURING INSTALLATION. C. Install the packing (2) in the cap (1). Gently roll the packing cap (3) so that it will form around the packing. Install the packing cap on the packing. D. Lightly lubricate the inside diameter of the poppet (6) with silicone grease (#33). Install the poppet and the spring (5) in the cap (1). E. Install the quad rings (9) in the grooves of the rod (14). Lightly lubricate the quad rings (on the rod) with silicone grease (#33).
F. Install the rod (14) in the valve body (12). Install the packing (13) in the packing groove of the valve body. Make sure that the pivot is installed in accordance with the dimensional requirement of Figure 3. G. Install the float assembly (items 17, 18 and 19) in the sump (21). H. Hook the pin on the float (19) into the groove of the rod (14). Line up the hole of the pivot (15) with the holes in the lever of the float and install the pin (16). I. Make sure that the packing (13) is correctly seated in its groove on the valve body (12). Secure the valve body to the sump with the screws (10) and the washers (11). J. Install the cap (1) on the valve body (12) and secure it with the screws (7) and the washers (8). K. Assembling the Plunger Assembly Install the plunger (22.1) with new packings (22.4) and a new backup ring (22.3) in the plug (22.1). Install the ring (22.4) on the plunger. L. Install the plunger assembly (22) in the sump (21). Tighten the plug (22.1) securely. TESTING NOTE: Prior to testing, the vessel in which the water sump control valve is installed must be drained in accordance with the applicable instructions, and the valve must be disconnected and removed from the vessel. 1. Leakage and Functional Test A. Connect a regulated air pressure source (85 psig maximum) to the PRESSURE INLET port. B. Connect a pressure gage to the PRESSURE OUTLET port. C. Connect an open line to the VENT port. WARNING: AVIATION FUEL IS FLAMMABLE AND TOXIC TO YOUR EYES, YOUR SKIN, AND YOUR RESPIRATORY TRACT. SKIN AND EYE PROTECTION IS REQUIRED. AVOID REPEATED OR PROLONGED CONTACT. KEEP AWAY FROM OPEN FLAMES OR OTHER IGNITION SOURCES.
D. Immerse the valve with its mounting flange horizontal and facing upward in a container of clean aviation fuel. Pressurize the inlet port to 60 psig. E. The float must remain in its fully down position. No air bubbles (indicating external leakage) should be visible. F. Vent the test pressure to 0 psig. Remove the water sump control valve from the container and blow it dry with shop air. G. Immerse the valve with its mounting flange horizontal and facing upward in a container of clean water. Do not pressurize the inlet port. H. The float should rise to its fully up position. I. Manually push the float to its fully down position and hold it down. Pressurize the inlet port to 60 psig. The pressure gage should indicate 60 psig. J. Release the float. Air should vent from the open line. The pressure gage should indicate 0 psig. K. Manually push the float to its fully down position and hold it down. The pressure gage should indicate 60 psig. L. Vent the test pressure to 0 psig. Remove the valve from the container and thoroughly dry it with shop air. Disconnect the valve from the test setup.
ILLUSTRATED PARTS LIST 1. General This section lists, describes, and illustrates all detail parts required for maintenance support of the Water Sump Control Valve. 2. Scope of Information A. The parts list 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. Abbreviations ASSY FIG. MOD REF Assembly. Figure. Modification. Reference item. KIT REPLACEMENT PARTS KITS AVAILABLE ITEMS IN KIT PART NUMBER DESCRIPTION (IPL Figure 2) KITF532-1 Seal Replacement 2, 3, 4, 9, 13 and 20 2702466 Overhaul 2, 3, 4, 6, 7, 8, 9, 10, 11, 13 and 20
FIG. DESCRIPTION MOD UNITS ITEM PART NUMBER 1 2 3 4 5 6 7 CODES PER ASSY 1 F532B VALVE, WATER SUMP CONTROL REF 1 F60W1812-1 CAP 1 2 2661058BD019 PACKING, PREFORMED 1 3 DW1304-018- CAP, PACKING 1 11-009SPECIAL 4 2661058A031 PACKING, PREFORMED 1 5 F60W1811 SPRING, COMPRESSION 1 6 F60W1810 POPPET 1 7 CAN500C10-28 SCREW, MACHINE 4 8 CMS35333-39 WASHER, LOCK 4 9 Q4008-366Y RING, QUAD 3 10 CAN500-8-14 SCREW, MACHINE 2 11 8743-516181 WASHER, FLAT 2 12 931200-101 BODY, VALVE (Aluminum alloy) 1 13 2661058A133 PACKING, PREFORMED 1 14 F60W1809 ROD 1 15 F60W1628? PIVOT 1 16 F60W1627 PIN, HINGE 1 17 CAN814-16D? PLUG 1 18 CMS29512-16 PACKING, PREFORMED 1? 19 F60W1649 FLOAT 1 20 2661058A266 PACKING, PREFORMED 1 21 F60W1622-2 SUMP (Aluminum alloy) 1 931021-102 SUMP (Aluminum alloy) (Alternate for 1 F60W1622-2) 22 2691216 PLUNGER ASSEMBLY 1 22.1 2691215 PLUG 1
FIG. DESCRIPTION MOD UNITS ITEM PART NUMBER 1 2 3 4 5 6 7 CODES PER 22.2 2691214 PLUNGER 1 22.3 CMS28774- RING, BACKUP 1 011 22.4 2661058BD0 PACKING, PREFORMED 2 11 22.5 1X3/32 RING, SPLIT 1 RR138 RING, SPLIT (Alternate for 1X3/32) 1 ASSY