Maintenance Manual 6-INCH INTERNAL VALVE F620 SERIES

Maintenance Manual 6-INCH INTERNAL VALVE F620 SERIES REVISION 1.1 03/15/2002

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...12/01/2001 Revision 1.1...03/15/2002 The total number of pages in this technical document is 22 consisting of the following: Title, A, 1 20 TABLE OF CONTENTS SUBJECT PAGE Introduction... 1 Description and Operation... 1 Fault Isolation... 6 Disassembly... 8 Cleaning... 9 Inspection... 10 Assembly... 11 Illustrated Parts List... 14 GROUND FUELING PRODUCTS GROUP Revision 1.1 03/15/2002 Page A

INTRODUCTION 1. General This manual provides component maintenance shop instructions for the 6-Inch Internal 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 primarily in English (U.S. customary) and selected Metric (SI) units. 1. Description DESCRIPTION AND OPERATION A. The 6-Inch Internal Valve (valve) (see Figure 1) is designed to normal and emergency shutoff functions and tank liquid level control with low surge, low pressure drop, and high reliability. When used with the F613 jet level sensor or F619B float operated pilot valve, fuel pressure provides the actuation force for opening and closing the valve during tank filling. B. The basic valve can be used for off-loading. Single or dual stage tank filling control is available by adding one or two pilot valves. A lug is provided for attachment of a lanyard to manually open the valve for emergency off-loading. 2. Operation (Refer to Figure 2) A. Starting Fuel Flow into the Tank Fuel flow into the tank commences when the upstream fuel pressure is applied both to the pilot valve(s) and to the valve inlet (main piston). When the fuel pressure applied to the pilot valve increases to approximately 6 psi, the pilot valve will open. When the pilot valve opens, the fuel trapped in the main piston chamber is relieved into the tank. The upstream pressure then opens the main piston, establishing flow into the tank. GROUND FUELING PRODUCTS GROUP Revision 1.1 03/15/2002 Page 1

Figure 1. 6-Inch Internal Valve C. Stopping Flow Fuel flow into the tank stops when the fuel level reaches the F613 jet level sensor shutoff point. Pressure to the pilot valve is relieved and the pilot valve closes. When the pilot valve closes, fuel fills the main piston chamber and the main piston closed by spring force and fuel pressure. C. Off-Loading Fuel Fuel off-loading is accomplished by applying air pressure to the power cylinder on the top of the valve. The power cylinder pulls the main piston to its open position. 3. Leading Particulars (Refer to Table 1) 4. Model Variations Refer to Table 2 for the available F620 series valve variations. Refer to the ILLUSTRATED PARTS GROUND FUELING PRODUCTS GROUP Revision 1.1 03/15/2002 Page 2

LIST section for additional details. GROUND FUELING PRODUCTS GROUP Revision 1.1 03/15/2002 Page 3

Figure 2. Flow Diagram GROUND FUELING PRODUCTS GROUP Revision 1.1 03/15/2002 Page 4

Table 1. Leading Particulars Service...Automotive and Aviation Fuels Operating Pressures Loading...5 to 150 psi Off-Loading (air pressure)...50 to 150 psi Pressure Drop (approximate) (600 gpm) Loading...4.5 psi Off-Loading...1.5 psi Flow Rate (maximum)... 1200 gpm Jet Sensor Flow Rate (approximate) (15 psi)... 0.5 gpm Fluid Temperature... 40 to 140 F ( 54 to 60 C) Ambient Temperature... 40 to 140 F ( 54 to 60 C) Weight (basic model) (approximate)... 26 pounds (11,8 kg) Envelope Dimensions...See Figure 3 Table 2. Model Variations MOD LETTER (Basic) A B C D E G Z DESCRIPTION Manual or air operated valve (no pilot valves, for off-loading only) Single Stage Pilot Control Adds primary pilot valve for simple automatic shutoff Dual Stage Pilot Control Adds primary and secondary pilot valves for accurate automatic shutoff Adds aluminum alloy weld ring Without weld sump Adds 6-inch x 90-degree Victualic elbow Adds stainless steel weld sump Without weld sump, mounting hardware, or interface seals GROUND FUELING PRODUCTS GROUP Revision 1.1 03/15/2002 Page 5

Figure 3. Envelope Dimensions GROUND FUELING PRODUCTS GROUP Revision 1.1 03/15/2002 Page 6

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 BOTTOM FILLING OPERATION Valve will not open Valve will not open and close Insufficient fuel pressure at pilot valve (40, IPL Figure 1) Metering rod (26) missing Jammed main piston (22) due to contamination Excessively worn or contaminated quad ring (5) Excessively worn or contaminated packing (8) Check and correct the air pressure supply. Replace the metering rod. Overhaul the valve. Replace the quad ring. Replace the packing. Valve will not close Metering rod (26) missing Replace the metering rod. Air pressure not completely exhausted Retaining ring (14) missing Check and correct the air pressure supply. Replace the retaining ring. GROUND FUELING PRODUCTS GROUP Revision 1.1 03/15/2002 Page 7

Table 3. Fault Isolation (continued) FAULT POSSIBLE CAUSE CORRECTIVE ACTION BOTTOM FILLING OPERATION Leakage when valve is closed (NOTE: Leakage of up to 20 cc/minute is allowed.) Fuel in air system Air leakage OFF-LOADING OPERATION Valve will not open Contaminated pilot valve (40) Excessively worn or contaminated quad ring (5) Excessively worn or contaminated packing (8) Excessively worn or contaminated main piston seat Excessively worn or contaminated quad ring (5) Excessively worn or contaminated packing (8) Excessively worn or contaminated quad ring (5) Excessively worn or contaminated packing (8) Damaged plug (32) Insufficient fuel pressure at pilot valve (40) Damaged (leaking) pilot valve diaphragm (4, IPL Figure 2) Metering rod (26, IPL Figure 1) missing Jammed main piston (22) due to contamination Overhaul or replace the pilot valve. Replace the quad ring. Replace the packing. Overhaul the valve. Replace the quad ring. Replace the packing. Replace the quad ring. Replace the packing. Replace the plug. Check and correct the air pressure supply. Overhaul or replace the pilot valve. Replace the metering rod. Overhaul the valve. GROUND FUELING PRODUCTS GROUP Revision 1.1 03/15/2002 Page 8

Table 3. Fault Isolation (continued) FAULT POSSIBLE CAUSE CORRECTIVE ACTION OFF-LOADING OPERATION Surging fuel flow Valve will not close Insufficient air pressure in cover (2) Metering rod (26, IPL Figure 1) incorrectly adjusted Jammed main piston (22) due to contamination Air pressure not completely exhausted Damaged (deformed) seal (21) Damaged plug (32) Check and correct the air pressure supply. Adjust the metering rod (refer to the ASSEMBLY section.) Overhaul the valve. Check and correct the air pressure supply. Replace the seal Replace the plug. Internal leakage Damaged (deformed) seal (21) Replace the seal Damaged seat on main piston (22) or contamination of sealing surfaces Overhaul the valve. DISASSEMBLY 1. Disassembly of the Valve (Refer to IPL Figure 1) A. Unscrew and remove the plugs (31) or the pilot valve(s) (41). Remove the packing(s) (29). Refer to paragraph 2 for disassembly of the pilot valve(s). B. Unscrew and remove the rod (26). C. Remove the screws (24), the washers (25) and the cap (4). Remove the packing (15) from the cap (4). WARNING: THE ADAPTER (18) IS UNDER HEAVY SPRING PRESSURE. YOU MUST BE VERY CAREFUL TO RESTRAIN IT DURING REMOVAL. GROUND FUELING PRODUCTS GROUP Revision 1.1 03/15/2002 Page 9

D. Remove the bolts (28), the washers (39) and the adapter (18). Remove the packing (35) from the adapter. E. Remove the piston (22) and the spring (23) from the valve body (16). Remove the packing (20) and the seal (21) from the piston. F. Compress the spring (13) by pressing the outer spring retainer (11). Remove the retaining ring (14). NOTE: The rod (1) and the cover (2) are bonded together with adhesive and cannot be separated. If either part is damaged, both parts must be replaced. G. Pull the rod (1) and the cover (2) out of the cap (4). H. Remove the quad ring (5) and the felt strip (6) from the cap (4). I. Remove the screws (12), the inner spring retainer (11), the spring (10), the washer (9), the backup rings (7) and the packing (8) from the cap (4). J. Remove the screws (19) and the screen (17) from the valve body (16). K. Remove the plug (32) from the valve body (16). 2. Disassembly of the Pilot Valve (Refer to IPL Figure 2) A. Remove the screws (1), the washers (2) and the cover (3) from the fitting (7). Remove the diaphragm (4). B. Remove the retaining ring (9), the washer (5), the spring (6) and the poppet (8) from the fitting (7). 1. Cleaning Materials CLEANING Refer to Table 4 for recommended cleaning materials. Suitable equivalent cleaning materials may be substituted for the items listed. GROUND FUELING PRODUCTS GROUP Revision 1.1 03/15/2002 Page 10

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. Brush all threaded areas. Use a Teflon pick to remove obstructions from the ports, the seal or packing grooves and the flow 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. 1. General INSPECTION A. Under strong light and magnification, visually check all parts in accordance with the general criteria specified in paragraph 2 below. GROUND FUELING PRODUCTS GROUP Revision 1.1 03/15/2002 Page 11

B. Repair minor damage in accordance with local standard procedures. If damage is major or beyond simple repair, replace the part rather than attempt any extensive repairs. 2. Component Checks (Refer to Table 5) Table 5. Component Checks DESCRIPTION (IPL Figure 1 Item No.) CHECK CRITERIA General 1) Visually check all parts as applicable for nicks, cracks, cuts, burrs, corrosion, breaks, scoring, deformation, dents, thread damage, or any other obvious defects. 2) Make sure that the ports, passages, recesses and sealing grooves are clean and unobstructed. 3) Check all sealing and seating surfaces for damage or corrosion which would affect sealing. Main Piston (1-22) 1) Replace the piston if there is scoring on the outside diameters of the piston body. 2) Replace the piston if bare metal shows through the anodized surface. 3) The bonded seal in the seating face must not have any cut, crack or chip which would affect sealing. Valve Body (1-16) Check the main piston seating surface for any damage or corrosion which would affect sealing. ASSEMBLY 1. Replacement Parts Kits Refer to the ILLUSTRATED PARTS LIST section for recommended replacements parts kit information. 2. Assembly Materials Refer to Table 6 for recommended assembly materials. Suitable equivalent materials may be substituted for the items listed. GROUND FUELING PRODUCTS GROUP Revision 1.1 03/15/2002 Page 12

3. Assembly of the Pilot Valve A. Lubrication Prior to assembly, lightly lubricate the diaphragm and the screw threads with petrolatum. Table 7. Recommended Assembly Materials DESCRIPTION SPECIFICATION SOURCE Adhesive R313 or Epoxipatch 1C Commercially available Petrolatum Commercially available Tape, Teflon (unsintered) 0.38 (±0.13) inch wide x 0.004 inch thick Commercially available Thread Locking Compound Loctite, Grade 242 Commercially available B. Assembly Procedure (Refer to IPL Figure 2) 1) Install the poppet (8), the spring (6) and the washer (5) in the fitting (7). Secure the parts by installing the retaining ring (9). 2) Put the diaphragm (4) on the fitting (7) with its cupped side down. Install the cover (3) and secure it with the screws (1) and the washers (2). 4. Assembly of the Valve A. Lubrication Prior to assembly, lightly lubricate the seals, the packings and the screw threads with petrolatum. B. Assembly Procedure (Refer to IPL Figure 1) 1) Wrap the screen (17) tightly around the valve body (16), approximately in the center of the window. Secure the screen with the screws (18). Slight bending of the screen wires is permitted to provide a good fit. 2) Install the packing (8), the backup rings (7), the washer (9), the spring (10) and the inner spring retainer (11) in the cap (4). Secure the parts by installing the screws (12). 3) Install the felt strip (6) and the quad ring (5) in the grooves of the cap (4). GROUND FUELING PRODUCTS GROUP Revision 1.1 03/15/2002 Page 13

NOTE: When the rod (1) and the cover (2) are bonded together with adhesive, they cannot be separated. If either part is damaged, both parts must be replaced. 4) Apply epoxy adhesive to the threads of the rod (1). Thread the rod into the cover (2) and tighten it securely. Allow sufficient time for the adhesive to cure. 5) Install the rod (1) with the cover (2) in the cap (4). 6) Position the spring (13) and the outer spring retainer (11) over the rod (1). Compress the spring by pressing the spring retainer and secure the parts by installing the retaining ring (14). 7) Install the packing (20) and the seal (21) on the piston. Install the piston (22) and the spring (23) in the valve body (16). 8) Install the packing (35) in the packing groove of the adapter (18). Install the adapter on the valve body (16) and secure it with the bolts (28) and the washers (39). 9) Install the packing (5) in the packing groove of the cap (4). Install the cap on the adapter (18) and secure it with the screws (24) and the washers (25). 10) Install the rod (26) and tighten it as necessary to meet the dimensional requirement shown in Figure 4. Figure 4. Adjusting the Rod GROUND FUELING PRODUCTS GROUP Revision 1.1 03/15/2002 Page 14

11) Install the packings (29) and the pilot valve(s) (27) or plug(s) (31). 12) Apply Teflon tape to the threads of the plug (32). Install the plug in the valve body (16) and tighten securely. 1. General ILLUSTRATED PARTS LIST This section lists, describes, and illustrates all detail parts required for maintenance support of the 6-Inch Internal Valve. 2. Scope of Information A. The listing is indented 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 indicates the parts usage with respect to the end item. When the MOD column is blank, the part usage is applicable to all versions unless otherwise specified in the DESCRIPTION column. Modification codes used in this manual are listed in the following table. C. How to Identify a Part 1) When the part number is known: Refer to the parts list for the item number, description, modification codes, and quantity. Refer to the illustration to verify the physical appearance and location of the part. 2) When the part number is not known: Review the illustrations to identify the part by physical appearance and location. Refer to the accompanying parts list to obtain the part number, description, modification codes, and quantity. D. Abbreviations ASSY FIG. IPL MOD REF Assembly. Figure. Illustrated Parts List. Modification. Reference item. GROUND FUELING PRODUCTS GROUP Revision 1.1 03/15/2002 Page 15

IPL Figure 1. 6-Inch Internal Valve (Sheet 1 of 2) GROUND FUELING PRODUCTS GROUP Revision 1.1 03/15/2002 Page 16

IPL Figure 1. 6-Inch Internal Valve (Sheet 2 of 2) GROUND FUELING PRODUCTS GROUP Revision 1.1 03/15/2002 Page 17

FIG. ITEM PART NUMBER 1 2 3 4 5 6 7 DESCRIPTION MOD CODES UNITS PER ASSY 1 F620 VALVE, INTERNAL, 6-INCH... REF 1 2681180 C ROD... 1 2 2681181 C COVER... 1 4 2681183-2 C CAP... 1 5 Q4325-366Y C RING, QUAD... 1 6 CMS28932C05-05 C STRIP, FELT... 1 7 2681184 C RING, BACKUP... 2 8 2661058BD206 C PACKING, PREFORMED... 1 9 2681186 C WASHER, FLAT... 1 10 2681187 C SPRING, COMPRESSION... 1 11 2681188 C RETAINER... 2 12 LP505-10-8 C SCREW, SELF-LOCKING (03038)... 2 13 2681189 C SPRING, COMPRESSION... 1 14 CMS16633-4050 C RING, RETAINING... 1 15 2661058A157 C PACKING, PREFORMED... 1 16 2701292 C BODY, VALVE... 1 17 2641414-2 C SCREEN... 1 18 2701294 C ADAPTER... 1 19 CMS24622-17 C SCREW, SELF-TAPPING... 2 20 2661058BD441 C PACKING, PREFORMED... 1 21 2681171-441 C SEAL... 1 22 2701293 C PISTON... 1 23 2701399 C SPRING, COMPRESSION... 1 24 CAN502-10-12 C SCREW, MACHINE... 6 25 CAN935-10 C WASHER, LOCK... 6 CMS35338-43 C WASHER, LOCK... 6 26 2701295 C ROD... 1 28 CAN4-6 C BOLT, MACHINE... 12 29 CMS29512-10 C PACKING, PREFORMED... 2 30 2661058A365 C PACKING, PREFORMED (Supplied... 2 separately) (Not used on Mod Z) 31 CAN814-10D C PLUG (Quantity 1 on Mod A) (Not used... 2 on Mod B) 32 CAN932-4 C PLUG... 1 35 2661058A166 C PACKING, PREFORMED... 1 GROUND FUELING PRODUCTS GROUP Revision 1.1 03/15/2002 Page 18

FIG. ITEM PART NUMBER 1 2 3 4 5 6 7 DESCRIPTION MOD CODES UNITS PER ASSY 1 37 2701296-1 C SUMP (Supplied separately)... (Not used on Mods C, D or Z) 1 2701296-2 C SUMP (Supplied separately)... G 1 38 2701365 C SEAL (Supplied separately) (Not used... 1 On Mod Z) 39 CAN960-416 C WASHER, FLAT... 12 CAN960-416 C WASHER, FLAT (Supplied separately)... 16 CAN960-416 C WASHER, FLAT (Supplied separately)... G,Z 12 40 CAN4-10 C BOLT, MACHINE (Supplied separately).. 16 (Not used on Mod C, G or Z) 41 2681193 C VALVE, PILOT (Quantity 2 on Mod B)... A,B 1 42 2681192-1 C ORIFICE... B 1 43 2661058A114 C PACKING, PREFORMED... B 1 44 2734207 C RING, WELD (Supplied separately)... C 1 45 MS90725-11 C BOLT, MACHINE (Supplied separately).. C 16 (Not used on Mod C) 46 2701919 C ELBOW (Supplied separately)... E 1 47 CMS90725-60 C BOLT, MACHINE (Supplied separately).. E 12 48 CAN935-616L C WASHER, LOCK (Supplied separately)... E 12 49 CMS35338-139 C WASHER, LOCK (Supplied separately)... G 16 50 CMS35650-3254 C NUT, PLAIN HEX (Supplied separately).. G 16 GROUND FUELING PRODUCTS GROUP Revision 1.1 03/15/2002 Page 19

IPL Figure 2. Pilot Valve GROUND FUELING PRODUCTS GROUP Revision 1.1 03/15/2002 Page 20

FIG. ITEM PART NUMBER 1 2 3 4 5 6 7 DESCRIPTION MOD CODES UNITS PER ASSY 2 2681193 VALVE, PILOT... A,B REF 1 LP35275-230 C SCREW, SELF-LOCKING... 6 2 CNAS620C6 C WASHER, FLAT... 6 3 2681197 C COVER... 1 4 2633219 C DIAPHRAGM... 1 5 CAN960C10L C WASHER, FLAT... 1 6 2681196 C SPRING, COMPRESSION... 1 7 2681194 C FITTING... 1 8 2813374-101 C POPPET... 1 9 CMS16633-4018 C RING, RETAINING... 1 OVERHAUL PARTS KIT AVAILABLE KIT PART NUMBER ITEMS IN KIT (IPL Figure 1) KITF620 5, 6, 8, 14, 15, 20, 21 and 29, IPL Figure 1 and 4, IPL Figure 2 GROUND FUELING PRODUCTS GROUP Revision 1.1 03/15/2002 Page 21