sm 64080

SM64080 September 2008 Applicable addition manuals: None

Maintenance & Repair Manual

Line Mounted Pressure Control Valves - 3 & 4”

Model 64080 Model 64124

Aerospace Group Conveyance Systems Division Carter® Brand Ground Fueling Equipment

SM64080 September 2008

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TABLE OF CONTENTS

Page

1.0 Introduction .........................................................................................................3 2.0 Equipment Description........................................................................................3 3.0 Table of Options..................................................................................................3 4.0 Disassembly........................................................................................................3 5.0 Inspection............................................................................................................5 6.0 Reassembly ........................................................................................................6 7.0 Test .....................................................................................................................8 8.0 Illustrated Parts Catalog......................................................................................9 Figure 1..........................................................................................................................11 Figure 2..........................................................................................................................13 Figure 3A .......................................................................................................................14 Figure 3B .......................................................................................................................14 Figure 4..........................................................................................................................15 Figure 5..........................................................................................................................15


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Maintenance, Overhaul & Test Instructions Carter® Models 64080 & 64124 Line Mounted Pressure Control Valves

1.0 INTRODUCTION

This manual furnishes detailed instructions covering the maintenance and overhaul of Eaton’s

Carter brand Models 64080 and 64124 line mounted pressure control valves.

2.0 EQUIPMENT DESCRIPTION

Carter brand Model 64080 (3") and Model 64124 (4") line mounted pressure control valves are designed to provide a nominal constant pressure at a remote sense port as a function of the air reference pressure provided.

Refer to the Table of Options in paragraph 3.0 for available options. The unit is a normally closed spring-loaded piston valve. With the application of an air reference pressure to the appropriate port, the valve will open to allow flow downstream. The reference pressure should be approximately 20-35 psi greater than the desired fuel control pressure. For example, if the desired downstream-regulated pressure is 50 psi, the air reference pressure supplied should be nominal 70 to 85 psi. As the flow of fuel increases and the pressure at the sense point begins to increase, it will be sensed at the fuel sense port on the unit. This fuel pressure reacting against the smaller piston diameter, combined with the spring force, balances the air reference pressure reacting against the larger diameter of the piston. The piston, thereby regulating the flow through the unit, achieves a relatively constant pressure. Opening time of the valve is fixed and controlled by the orifice in the fuel sense port. The check valve located within the fuel sense port allows restricted flow out of the piston chamber and relatively unrestricted flow into the chamber. Hence upon sensing a rapid build up of downstream pressure in excess of approximately 1.5 psi will cause the check valve to open, flooding the piston chamber, causing the valve to close quickly in response.

The adjustable orifice in the air reference port controls closing time.

The air reference pressure is normally routed through a three-way deadman valve which when released vents the air pressure from the unit. The line pressure reacting upon the differential areas of the piston, aided by the spring, will cause the unit to close.

The unit has a vent port located next to the air reference port. This port provides the capability of draining off any seal leakage, when it occurs, to keep from getting fuel in the air system of the refueling vehicle. In addition, the unit has a port designed to allow bleeding of the fuel sense line of air. This port is adjacent to the fuel sense port and can be plumbed into a drain tank with a small petcock or plugged. The unit should be installed such that the bleed port is placed in an upward direction to facilitate the bleeding operation. This will also make sure the leakage vent port is then placed in a downward direction. The vent port, if desired can be plumbed to a low pressure area such as a slop tank or pump inlet to keep any possible leakage contained.

The 64124 differs from the previous 61024 only in that the newer units incorporates a "cartridge" type insert for installing the two smaller piston seals within the body. This facilitates the assembly procedure. All replacement parts are the same. In addition, Victaulic inlet and outlet connections are now available.

3.0 TABLE OF OPTIONS

Option Letter Description

Option Letter Description

B Adds trapped pressure relief valve E Adds flange outlet, victaulic inlet C Adds spacer to make length same as Whittaker

F370 (4” valve only) DE Adds victaulic inlet & outlet

D Adds flange inlet, victaulic outlet

4.0 DISASSEMBLY

NOTE: Before proceeding, make sure safety glasses are worn.

64080- 3” VALVE ASSEMBLY – Refer to Figure 1 for this operation.

4.1 Remove Check Valve Housing (1-29) followed by Check Valve (1-32), O-ring (1-31) and Gasket (1-30) and Spring (1-33). Discard O-ring (1-31) and Gasket (1-30).

4.2 Remove Screws (1-6A) from unit with flanged outlet or (1-6B) from unit with the Victaulic outlet and remove Housing (1-2A) or (1-2B) from


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Housing (1A-1D). Remove and discard O-ring (1-3) and O-ring (1-5) and Seal (1-4).

4.3 Rotate Outer Piston (1-11), if necessary to gain access to the four Screws (1-7).

4.3.1 Screws (1-7) are a self locking type screw that utilizes a nylon insert in the threads to affect the resistance required to provide the locking. They are designed to be reused a number of times before losing their locking effectiveness. Using a torque wrench, remove Screws (1-7) from the Housing (1A-1D) measuring the torque during removal. If the torque is less than 2 in lb. (0.023 m kg) discard the screw and replace it during reassembly.

4.3.2 Discard O-rings (1-8).

4.3.3 Grasp Outer Piston (1-11) and remove the entire piston/shaft assembly from the outlet of the unit.

4.3.4 Remove and discard O-rings (1-15) and (1-16) from the shoulder and groove of the Piston Retainer (1-12).

WARNING

Before proceeding further beware that the Outer Piston and the attaching parts are heavily spring loaded and a vise or similar should be used to safely disassemble the piston assembly.

4.3.5 As indicated above, a vise or woodworkers clamp is required to proceed further. Wood blocks should be used to secure the piston.

Assemble such that an axial load is exerted yet allows access to both Nuts (1-9).

CAUTION: Be certain the piston assembly is securely held in place and cannot slip, allowing the unit to forcibly separate when the first nut (1-9) is removed. Forcible separation may cause personal injury. Be careful not to damage the sealing surface of the inner or outer piston. Damage to these surfaces will cause leakage and may cause regulator malfunction.

NOTE: Shaft (1-19) and nut (1-9) are both stainless steel. Nut (1-9) also includes a locking element. Due to this combination there is the possibility when these items are disassembled that the threads may gall or become damaged beyond repair. If it is necessary to disassemble these items replace both nuts (1-9) and consider replacing the shaft (1-19).

4.3.6 With the assembly securely clamped in place, carefully remove Nut (1-9) from the piston assembly, use Lockease or similar as an aid in removing the nut. Remove Washer (1-10) from piston assembly. Slowly open the clamping device allowing the spring force to cause the inner piston assembly to follow the

clamp until all spring force is relieved. Then carefully remove the clamp and lift the Inner Piston (1-23) from the Spring (1-18). Remove the two bronze Washers (1-20) from the Inner Piston (1-23) then remove Spring (1-18) and Teflon Washer (1-17B) from the Guide (1-17). Remove O-ring (1-22) and Washer (1-21) from the end of Shaft (1-19). Discard O-ring (1-22).

4.3.7 Using two thin 3/8-24 UNF-2B nuts as jam nuts on the shaft (1-19) where Nut (1-9) was removed above, remove Nut (1-9) and Washer (1-10) retaining the outer Piston (1-11) from the Shaft (1-19).

4.3.8 Remove Screws (1-17A) from the spring Guide (1-17) to remove Seal (1-14) and O-ring (1-13) from retainer. Discard O-ring (1-13).

4.4 Remove Screws (1-24) and then pull out Seal Housing (1-25) and Seal Retainer (1-28) with Seals (1-27) and O-rings (1-26). Discard Seals (1-27) and O-rings (1-26).

Note: It is recommended the user upgrade to the new seal cartridge. The new design with the energized Seal (1-27) and O-Ring (1-26) are included in the overhaul kit KD64080-1. These seals will not work with the old-style cartridge. Request a -4 kit for hardware items (1-25 & 1-28) to complete the upgrade. This configuration provides a more robust seal, reducing leakage and frequency for overhaul of the seal cartridge.

4.4.1 Older Units Seal Cartridge: Remove Screws (1-24) and then pull out Seal Housing Retainer (1-25A). Then remove and discard Seals (1-27A) and O-rings (1-26) and (1-28A).

4.5 Using an Allen key, remove Orifice Screw (1-34) and Spring (1-35).

4.6 Do not remove Plug(s) (1-36) from the Housing unless replacement is needed.

4.7 It is not necessary to remove Relief Valve (1-37) Option “B” (if equipped) from the Housing unless replacement is needed.

4.8 64124- 4” VALVE ASSEMBLY – Refer to Figure 2 for this operation.

4.8.1 Remove Check Valve Housing (2-29) followed by Check Valve (2-32), O-ring (2-31) and Gasket (2-30) and Spring (2-33). Discard O-ring (2-31) and Gasket (2-30).

4.9 Rotate Outer Piston (2-11), if necessary to gain access to the four Screws (2-7).

4.9.1 Screws (2-7) are a self locking type screw that utilizes a nylon insert in the threads to affect the resistance required to provide the locking. They are designed to be reused a number of times before losing their locking effectiveness. Using a torque wrench, remove Screws (2-7) from the Housing (2E-2J) measuring the torque during removal. If the torque is less than 2 in lb. (0.023 m


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kg) discard the screw and replace it during reassembly. Set aside Washers (2-8) for reuse.

4.9.2 Grasp Outer Piston (2-11) and remove the entire piston/shaft assembly from the outlet of the unit.

4.9.3 Remove and discard O-rings (2-15) and (2-16) from the shoulder and groove of the Piston Retainer (2-12).

WARNING

Before proceeding further beware that the Outer Piston and the attaching parts are heavily spring loaded and a vise or similar should be used to safely disassemble the piston assembly.

4.9.4 As indicated above, a vise or woodworkers clamp is required to proceed further. Wood blocks should be used to secure the piston.

Assemble such that an axial load is exerted yet allows access to both Nuts (2-9).

CAUTION: Be certain the piston assembly is securely held in place and cannot slip, allowing the unit to forcibly separate when the first nut (2-9) is removed. Forcible separation may cause personal injury. Be careful not to damage the sealing surface of the inner or outer piston. Damage to these surfaces will cause leakage and may cause regulator malfunction.

NOTE: Shaft (2-19) and nut (2-9) are both stainless steel. Nut (2-9) also includes a locking element. Due to this combination there is the possibility when these items are disassembled that the threads may gall or become damaged beyond repair. If it is necessary to disassemble these items replace both nuts (2-9) and consider replacing the shaft (2-19).

4.9.5 With the assembly securely clamped in place, carefully remove Nut (2-9) from the piston assembly, use Lockease or similar as an aid in removing the nut. Remove Washer (2-10) from piston assembly. Slowly open the clamping device

allowing the spring force to cause the inner piston assembly to follow the clamp until all spring force is relieved. Then carefully remove the clamp and lift the Inner Piston (2-23) from the Spring (2-18). Remove the two bronze Washers (2-20) from the Inner Piston (2-23) then remove Spring (2-18) and Teflon Washer (2-17B) from the Guide (2-17). Remove O-ring (2-22) and Washer (2-21) from the end of Shaft (2-19). Discard O-ring (2-22).

4.9.6 Using two thin 3/8-24 UNF-2B nuts as jam nuts on the shaft (2-19) where Nut (2-9) was removed above, remove Nut (2-9) and Washer (2-10) retaining the outer Piston (2-11) from the Shaft (2-19).

4.9.7 Remove Screws (2-17A) from the spring Guide (2-17) to remove Seal (2-14) and O-ring (2-13) from retainer. Discard O-ring (2-13).

4.10 Remove and discard Seal (2-4) and O-ring (2-5).

4.11 Remove Screws (2-24) and then pull out Seal Housing (2-25) and Seal Retainer (2-28) with Seals (2-27) and O-rings (2-26). Discard Seals (2-27) and O-rings (2-26).

Note: It is recommended the user upgrade to the new seal cartridge. The new design with the energized Seal (2-27) and O-Ring (2-26) are included in the overhaul kit KD64124-1. These seals will not work with the old-style cartridge. Request a -4 kit for hardware items (2-25 & 2-28) to complete the upgrade. This configuration provides a more robust seal, reducing leakage and frequency for overhaul of the seal cartridge.

4.11.1 Older Units Seal Cartridge: Remove Screws (2-24) and then pull out Seal Housing Retainer (2-25A). Then remove and discard Seals (2-27A) and O-rings (2-26) and (2-28A).

4.12 Using an Allen key, remove Orifice Screw (2-34) and Spring (2-35).

4.13 Do not remove Plug(s) (2-36) from the Housing unless replacement is needed.

4.14 It is not necessary to remove Relief Valve (2-37) Option “B” (if equipped) from the Housing unless replacement is needed.

5.0 INSPECTION

5.1 It is recommended that all O-rings and Seals be replaced upon every overhaul. Inspect all metal parts for dings, gouges, abrasions, etc. On all parts except Inner Piston (1-23 or 2-23) and Outer Piston (1-11 or 2-11), use 320 grit paper to smooth and remove sharp edges. Carefully inspect the outer diameters of both the Inner Piston (1-23 or 2-23) and Outer Piston (1-11 or 2-11) for scratches and other damage that will cause leakage. Check the "knife" edge of the Outer Piston (1-11 or 2-11) where it comes in contact with O-ring (1-16 or 2-16). This edge should be

smooth and free of dings and other imperfections. The outer diameters of both the Inner Piston (1-23 or 2-23) and the Outer Piston (1-11 or 2-11) can be polished to remove minor scratches by using a very fine emery cloth while the parts are rotated. Do not polish local areas of these diameters. By using the Shaft (1-19 or 2-19) as a fixture, both pistons can be installed in a portable drill held in a vise to achieve rotation. Do not break through the hard-anodized surface of the part. If scratches are too pronounced, the parts should be replaced.


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5.2 Nuts (1-9) or (2-9) should not be reused.

6.0 REASSEMBLY

Reassembly is accomplished in essentially the reverse order of disassembly. A light coat of petroleum jelly may be used during overhaul but do not use any other type of lubricant, ONLY PETROLEUM JELLY.

Note: Lightly lubricate all O-rings except O-Ring (1-5) or (2-5) and O-Ring (1-28A) or (2-28A) [old seal cartridge design] to be installed dry).

6.1 Make certain all components are clean and free from oil, grease, or any other corrosion resistant compound on all interior or exterior surfaces. Wash all parts with cleaning solvent, Federal Specification P-D-680, and dry thoroughly with a clean, lint-free cloth or compressed air.

6.2 Use Vibra-Seal or equal on male threads during reassembly. Do NOT use Teflon tape.

WARNING:

Use cleaning solvent in a well-ventilated area. Avoid breathing of fumes and excessive solvent contact with skin. Keep away from open flame.

6.3 64080- 3” VALVE ASSEMBLY- Refer to Figure 1 for this operation.

6.3.1 Seal Cartridge older units: Place O-rings (1-26) into the grooves of the Seal Housing Retainer (1-25A) outside diameter. Install O-rings (1-28A) in O-ring grooves on inside diameter of Housing. DO NOT LUBRICATE. Next install Piston Seals (1-27A) in inside diameter grooves over O-rings (1-28A) per Figure 3A. Smooth the combination of the Seal and O-ring (1-28A) with the finger to assure that they are installed completely in the seal grooves. Apply a light coat of lube and then insert the assembly into the main Housing (1A-1D) with the “notch” on (1-25A) oriented as shown on Figure 1 in the flow path for the check valve port “A”.

6.3.2 Install Screws (1-24) and torque to 18 ± 2 in.-lb. (21 ± 2 kg-cm). It will be necessary to condition seals with seal run-in tool AF42208-1 as described below.

Note: It is recommended the user upgrade to the new seal cartridge. The new design with the energized Seal (1-27) and O-Ring (1-26) are included in the overhaul kit KD64080-1. These seals will not work with the old-style cartridge. Request a -4 kit for hardware items (1-25 & 1-28) to complete the upgrade. This configuration provides a more robust seal, reducing leakage and frequency for overhaul of the seal cartridge and does not require polishing.

6.3.3 It is recommended that seal "run-in" tool, AF42208-1, be used to condition the Seals (1-27A) after installation. The tool can be procured through your

Carter distributor. The tool can be used with a hand drill to accomplish the run-in task as follows:

1. With the run-in tool attached to a hand drill, carefully insert the tool into the first Inner Piston Seal (1-27A) and using a low speed, push the tool into the unit until the piston passes through the second Inner Piston Seal (1-27A). The tool should be kept such that the piston portion of the tool makes contact only with the Seals (1-27A) in the Housing (1A-1D) and does not make metal to metal contact.

2. Carefully move the tool axially over a stroke of about 0.50 inch (12.7 mm) in and out maintaining contact with both Seals (1-27A) for about one minute. The speed of the drill should be maintained at a low to medium RPM.

3. Remove the tool.

6.3.4 Seal Cartridge newer units: O-rings (1-26) should be fitted onto the grooves of Seal Retainer (1-28). The lubricated Inner Piston Seals (1-27) should be installed on the inside diameter of the Seal Retainer (1-28) per Figure 3B. Now insert the retainer assembly into the main Housing (1A-1D) then install Housing (1-25) with the “notch” on oriented as shown on Figure 1 in the flow path for the check valve port “A”. Be careful not to damage the seals during installation.

6.3.5 Seat the Seal Housing (1-25) into the main Housing (1A-1D) by installing Screws (1-24). Torque Screws (1-24) to 18 ± 2 in.-lb. (21 ± 2 kg-cm). When properly installed, it is not necessary to polish the new type seals.

NOTE:

Shaft (1-19) and Nut (1-9) are both stainless steel. Nut (1-9) also includes a locking element. Due to this combination there is the possibility when these items are disassembled that the threads may gall or become damaged beyond repair. If it was necessary to disassemble these items replace both nuts (1-9) and consider replacing the shaft (1-19).

6.4 Assemble Outer Piston (1-11) onto Shaft (1-19) using Washer (1-10) and Nut (1-9). Use two thin 3/8-24 UNF-2B nuts as jam nuts on the opposite end of the Shaft (1-19) while tightening Nut (1-9) to 195 ± 10 in.-lb. (225 ± 12 kg-cm).

6.4.1 Install O-ring (1-13) on Seal (1-14) and install in Retainer (1-12). The leg or hook end of the seal should point toward the Outer Piston (1-11). Press the seal into place very carefully in the retainer. Install Screws (1-17A) through spring Guide (1-17) and tighten screws equally.


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6.4.2 Apply a light coat of lube to inside ID of Seal (1-14) and slide the Retainer (1-12) onto Shaft (1-19).

6.4.3 Install Teflon Washer (1-17B) on the shoulder of the spring Guide (1-17).

6.4.4 Place Washer (1-21) over the end of the Shaft (1-19) and install O-ring (1-22) above the washer.

6.4.5 Install Spring (1-18) onto Guide (1-17). Place the two bronze Washers (1-20) on top of the spring and hold them in place by placing the Inner Piston (1-23) over Spring (1-18). Insert assembly into the clamping device used during disassembly. Compress the assembly and allow access to install the Washer (1-10) and Nut (1-9) on the end of the shaft and tighten to 195 ± 10 in.-lb. (225 ± 12 kg-cm).

6.4.6 Install the O-ring (1-15) into groove in Retainer (1-12). Install O-ring (1-16) over the end of the Retainer (1-12) to where it rests against the retainer’s shoulder.

6.4.7 Victaulic Outlet- Install O-ring (1-3) on the shoulder the Seal Housing (1-2B) and carefully insert into the main Housing (1B or 1D) so as not to cut O-ring (1-3). Rotate the Retainer (1-2B) to line up the six holes with the mating holes in the housing and install Screws (1-6B). Insert the non-lubricated O-ring (1-5) into the groove between main housing and seal housing. Install Seal (1-4) over O-ring (1-5) so the flange end of the Seal (1-4) is on the outlet side with the "leg" of the seal pointing toward the unit inlet. Refer to Figure 4 for more detail.

6.4.8 Flange Outlet- Install O-ring (1-3) on the shoulder the Seal Housing (1-2A) and carefully insert into the main Housing (1A or 1C) so as not to cut O-ring (1-3). Rotate the Retainer (1-2A) to line up the six holes with the mating holes in the housing and install Screws (1-6A). Insert the non-lubricated O-ring (1-5) into the groove between main housing and seal housing. Install Seal (1-4) over O-ring (1-5) so the flange end of the Seal (1-4) is on the outlet side with the "leg" of the seal pointing toward the unit inlet. Refer to Figure 4 for more detail.

6.4.9 Insert piston assembly into the housing and rotate Outer Piston (1-11) to line up the four holes with the mating holes in the housing. Place O-rings (1-8) over Screws (1-7) and tighten in a cross manner.

6.5 Install Screw (1-34) and Spring (1-35) in Port “D” using an Allen key to tighten Screw (1-34) to bottom out. Then back out screw 3 - 4 complete turns. This should adjust closing time to approximately 2.5 to 3 seconds. Finer adjustment may be necessary during flow testing.

6.6 Install Spring (1-33) in port “A”. Place O-ring (1-31) in groove of Check Valve (1-32) and install over Spring (1-33). Place Gasket (1-30) over Check Valve Housing (1-29) and thread into port “A”.

6.7 If either items (1-37) Option “B” or Plug(s) (1-36) were removed during disassembly, reinstall at this time.

6.8 64124- 4” VALVE ASSEMBLY- Refer to Figure 2 for this operation.

6.8.1 Seal Cartridge older units: Place O-rings (2-26) into the grooves of the Seal Housing Retainer (2-25A) outside diameter. Install O-rings (2-28A) in o-ring grooves on inside diameter of Housing. DO NOT LUBRICATE. Next install Piston Seals (2-27A) in inside diameter grooves over O-rings (2-28A) per Figure 3A. Smooth the combination of the Seal and O-ring (2-28A) with the finger to assure that they are installed completely in the seal grooves. Apply a light coat of lube and then insert the assembly into the main Housing (2E-2J) with the “notch” on (2-25A) oriented as shown on Figure 2 in the flow path for the check valve port “A”.

6.8.2 Install Screws (2-24) and torque to 18 ± 2 in.-lb. (21 ± 2 kg-cm). It will be necessary to condition seals with seal run-in tool AF42208-1 as described below.

Note: It is recommended the user upgrade to the new seal cartridge. The new design with the energized Seal (2-27) and O-Ring (2-26) are included in the overhaul kit KD64124-1. These seals will not work with the old-style cartridge. Request a -4 kit for hardware items (2-25 & 2-28) to complete the upgrade. This configuration provides a more robust seal, reducing leakage and frequency for overhaul of the seal cartridge and does not require polishing.

6.8.3 It is recommended that seal "run-in" tool, AF42208-1, be used to condition the Seals (2-27A) after installation. The tool can be procured through your Carter distributor. The tool can be used with a hand drill to accomplish the run-in task as follows:

1. With the run-in tool attached to a hand drill, carefully insert the tool into the first Inner Piston Seal (2-27A) and using a low speed, push the tool into the unit until the piston passes through the second Inner Piston Seal (2-27A). The tool should be kept such that the piston portion of the tool makes contact only with the Seals (2-27A) in the Housing (2E-2J) and does not make metal to metal contact.

2. Carefully move the tool axially over a stroke of about 0.50 inch (12.7 mm) in and out maintaining contact with both Seals (2-27A) for about one minute. The speed of the drill should be maintained at a low to medium RPM.

3. Remove the tool.

6.8.4 Seal Cartridge newer units: O-rings (2-26) should be fitted onto the grooves of Seal Retainer (2-28). The lubricated Inner Piston Seals (2-27) should be installed on the inside diameter of the Seal Retainer (2-28) per Figure 3B. Now insert the retainer assembly into the main Housing (2E-2J) then install


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Housing (2-25) with the “notch” on (2-25) oriented as shown on Figure 2 in the flow path for the check valve port “A”. Be careful not to damage the seals during installation.

6.8.5 Seat the Seal Housing (2-25) into the main Housing (2E-2J) by installing Screws (2-24). Torque Screws (2-24) to 18 ± 2 in.-lb. (21 ± 2 kg-cm). When properly installed, it is not necessary to polish the new type seals.

NOTE:

Shaft (2-19) and Nut (2-9) are both stainless steel. Nut (2-9) also includes a locking element. Due to this combination there is the possibility when these items are disassembled that the threads may gall or become damaged beyond repair. If it was necessary to disassemble these items replace both nuts (2-9) and consider replacing the shaft (2-19).

6.9 Assemble Outer Piston (2-11) onto Shaft (2-19) using Washer (2-10) and Nut (2-9). Use two thin 3/8-24 UNF-2B nuts as jam nuts on the opposite end of the Shaft (2-19) while tightening Nut (2-9) to 195 ± 10 in.-lb. (225 ± 12 kg-cm).

6.9.1 Install O-ring (2-13) on Seal (2-14) and install in Retainer (2-12). The leg or hook end of the seal should point toward the Outer Piston (2-11). Press the seal into place very carefully in the retainer. Install Screws (2-17A) through spring Guide (2-17) and tighten screws equally.

6.9.2 Apply a light coat of lube to inside ID of Seal (2-14) and slide the Retainer (2-12) onto Shaft (2-19).

6.9.3 Install Teflon Washer (2-17B) on the shoulder of the spring Guide (2-17).

6.9.4 Place Washer (2-21) over the end of the Shaft (2-19) and install O-ring (2-22) above the washer.

6.9.5 Install Spring (2-18) onto Guide (2-17). Place the two bronze Washers (2-20) on top of the spring

and hold them in place by placing the Inner Piston (2-23) over Spring (2-18). Insert assembly into the clamping device used during disassembly. Compress the assembly and allow access to install the Washer (2-10) and Nut (2-9) on the end of the shaft and tighten to 195 ± 10 in.-lb. (225 ± 12 kg-cm).

6.9.6 Install the O-ring (2-15) into groove in Retainer (1-12). Install O-ring (2-16) over the end of the Retainer (2-12) to where it rests against the retainer’s shoulder.

6.9.7 Victaulic or Flange Outlet- Insert O-ring (2-5) and Seal (2-4) directly into main Body (2E-2J). The flange end of the Seal (2-4) shall be on the outlet side with the "leg" of the seal pointing toward the unit inlet. Refer to Figure 4 for more detail.

6.9.8 Insert piston assembly into the housing and rotate Outer Piston (2-11) to line up the four holes with the mating holes in the housing. Place O-rings (2-8) over Screws (2-7) and tighten in a cross manner.

6.9.9 Install Screw (2-34) and Spring (2-35) in Port “D” using an Allen key to tighten Screw (2-34) to bottom out. Then back out screw 3 - 4 complete turns. This should adjust closing time to approximately 2.5 to 3 seconds. Finer adjustment may be necessary during flow testing.

6.10 Install Spring (2-33) in port “A”. Place O-ring (2-31) in groove of Check Valve (2-32) and install over Spring (2-33). Place Gasket (2-30) over Check Valve Housing (2-29) and thread into port “A”.

6.11 If either items (2-37) Option “B” or Plug(s) (2-36) were removed during disassembly, reinstall at this time.

6.12 Option C (4” Flange Adapter Assembly) - If equipped, replace Gasket (2-40) during reinstallation of valve.

7.0 TEST

7.1 The following test procedures will be accomplished after overhaul:

7.2 Test conditions

7.2.1 Test media shall be Stoddard Solvent (Federal Specification P-D-680), JP-4 per MIL-J-5624D at 75° + 15°F, Jet A or equivalent.

7.3 Functional Test

7.3.1 Flange both ends of the unit with shutoff valves, connect a 0-300 psi test fluid source to the inlet of the unit and to the Fuel Sense Port (A). Plug the bleed port (B). Connect a 0-125 psi air reference source to the unit, at port D, through a deadman control valve.

Actuate the deadman control valve to apply 125 psi air reference pressure to the air reference port.

Open the outlet shutoff valve and the bleed port (B). Supply 300 psi test fluid pressure to the inlet to fill the unit. Hold the unit such that the bleed port (B) is up to facilitate bleeding of all air from the inside of the unit.

Close the outlet valve, release the deadman valve and maintain the 300 psi pressure for a minimum of one minute while checking for external leakage. Reduce the inlet pressure to 5 psi and repeat the test. There shall be no evidence of external leakage.

7.3.2 Open outlet valve to relieve pressure. Remove the outlet flange. Rotate the unit such that the outlet is on top. Cover the outlet to contain any fuel flow. Apply 60 psi through the deadman valve. Release and re-apply the deadman several times, while observing the Outer Piston (1-11or 2-11). The


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Outer Piston shall stroke fully open with each application of the deadman and fully close when the deadman is released.

WARNING! Keep fingers clear of these moving parts.

Turn the unit over to drain the fluid from the outlet. Increase the inlet pressure to 5 psi for one minute. Increase the inlet pressure to 150 psi and measure liquid leakage at the outlet. The maximum allowable internal leakage is 10 cc/min.

7.3.3 Install the unit in a system capable of maintaining a flow rate of 600 US gpm with a deadhead pressure of 150 psi. The fuel sense port shall be connected to a downstream sense point with a gauge installed to determine control pressure. The unit shall be installed such that the bleed port is vertical and facing upwards. Start flow through the system by actuating the deadman and flow for approximately 2 minutes to bleed the main line of the system. Partially close a valve downstream of the sense point.

Open the bleed line valve to obtain a steady bleed flow. Allow the line to bleed until all signs of air are eliminated. Shutoff bleed line valve.

Open the downstream valve and actuate the deadman, with 75 psi air pressure, to establish flow of approximately 300 gpm with system deadhead pressure of 120 psi. The unit should open and assume a pressure control of approxi-mately 25-35

psi less than the air reference pressure (75 psi) at the downstream control point.

While flowing 300 gpm, release the deadman and measure the time required to reach zero flow. The time required can be adjusted by repositioning Orifice Screw (1-34 or 2-34) to 2-5 seconds. Factory setting of a new unit for opening time is 3 ± .5 seconds. Overshoot, the volume of fuel passing through the unit during closure shall not exceed 15 gallons at 300 gpm flow rate. If the overshoot exceeds the allowable amount, the closing time can be readjusted by turning Screw (1-34 or 2-34) counter-clockwise to increase the orifice size.

Also measure the time required to re-open from zero flow to 300 gpm. Opening time should be 5 - 10 seconds. The operating time will vary with system setup and adjustments but should be within the same range of times from unit to unit.

Establish a flow rate of 300 gpm and throttle down to zero in about 5 increments to stabilize at each flow rate. The stabilized pressure at the control point should be 50 psi or less. The unit should maintain a stable control at all times. Note that if the flow rate is reduced too rapidly, the unit may shutoff at a pressure higher than 50 psi. This is normal and is the surge control function of the unit.

With zero flow, close the downstream valve and apply the deadman. The locked-in pressure at the outlet shall not exceed 75 psi.

8.0 ILLUSTRATED PARTS CATALOG

Table 1.0 tabulates the parts and sub-assemblies comprising the 64080 3” line mounted pressure control valve. The item numbers of the table are keyed to the exploded views of the unit diagrammed in Figure 1.

Table 2.0 tabulates the parts and sub-assemblies comprising the 64124 4” line mounted pressure control valve. The item numbers of the table are keyed to the exploded views of the unit diagrammed in Figure 2.

TABLE 1.0

64080 3” Control Valve

Fig. Item Part Number Description Units/ Assy

Valve Option

Spares/10Units/yr.

1 1A 47202-1 3” sub-assembly, flanged both ends 1 Standard - 220801 3” Housing, flanged both ends 1 Standard - 1B 47204-2 3” sub-assembly, flanged inlet, Victaulic outlet 1 D - 220803 3” Housing, flanged inlet, Victaulic outlet 1 D - 1C 47204-3 3” sub-assembly, victaulic inlet, flanged outlet 1 E - 220802 3” Housing, Victaulic inlet, flanged outlet 1 E - 1D 47204-4 3” Sub-assembly, Victaulic both ends 1 DE - 220793 3” Housing, Victaulic both ends 1 DE - 2A 221193 Housing, Seal, flanged end 1 Standard, E - 2B 221191 Housing, Seal, Victaulic end 1 D, DE - 3 MS29513-042 O-ring 1 All 5 4 220665 Seal, Outer Piston 1 All 5 5 MS29513-151 O-ring 1 All 5 6A GF16997-18 Screw, flanged end 6 Standard, E - 6B GF16995-49 Screw, Victaulic end 6 D, DE -


10


Valve Option

Spares/10Units/yr.

1 7 220685-1250 Screw 4 All - 8 MS29513-008 O-ring 4 All 20 15 MS29513-038 O-ring 1 All 5 16 201201-231 O-ring 1 All 5 9-14 &

17-23 47347-1 Piston Assembly 1 All -

9 38NST188 Nut 2 All - 10 GF960C616L Washer 2 All - 11 220666 Piston, Outer 1 All - 12 221607 Retainer, Piston Seal 1 All - 13 203565 O-ring 1 All 5 14 221595 Seal, Shaft 1 All 5 17 221594 Guide 1 All - 17A NAS1351C04-4 Screw 6 All - 17B 5610-381-50 Washer, Teflon 1 All - 18 200757 Spring 1 All - 19 202290 Shaft, Piston 1 All - 20 5720-158-25 Washer, Bronze 2 All - 21 202291 Washer 1 All - 22 MS29513-012 O-ring 1 All 5 23 200759 Piston, Inner 1 All - 24 GF16997-32L Screw 4 All - Items 25A, 27A & 28A have been superseded by items 25, 27 & 28 25 222160 Housing, Seal 1 All - 25A 221307 Retainer, Housing, Seal 1 All - 26 MS29513-134 O-ring 2 All 10 27 222165 Seal, Inner Piston 2 All 5 27A 200758 Seal, Inner Piston 2 All 5 28 222161 Retainer, Seal 1 All - 28A MS29513-129 O-ring 2 All 5 29 205756-2 Housing, Check Valve 1 All - 30 MS29512-08 Gasket 1 All 5 31 MS29513-009 O-ring 1 All 5 32 205772 Check Valve 1 All - 33 200791 Spring 1 All - 34 220413 Control Screw 1 All - 35 220472 Spring 1 All - 36 5406-P-04 Plug 2 All (1 only on

Option B) -

37 206B-1 Valve, Trapped Pressure Relief 1 B -

KD64080-1 Kit - Contains the parts needed to overhaul the 64080 valve assembly – contains items 1-3, 1-4, 1-5, 1-8, 1-13, 1-14, 1-15, 1-16, 1-22, 1-26, 1-27, 1-30 and 1-31.

KD64080-2 Kit – Contains Piston Assembly 47347-1 for 3” valve– Contains items 1-9, 1-10, 1-11, 1-12, 1-13, 1-14, 1-17, 1-18, 1-19, 1-20, 1-21, 1-22 and 1-23.

KD64080-4 Kit – Contains the housing and retainer necessary to upgrade to the now standard seal cartridge design. Contains items – 1-25 and 1-28.

Notes: 1. All part numbers beginning with "GF" are interchangeable with those beginning with either "AN" or "MS". If the

"GF" is followed by three numbers it is interchangeable with and "AN" part, otherwise it is interchangeable with an "MS" part of the same number.

2. The recommended spare parts shown above are the number required to support 10 units for one year or each overhaul whichever is sooner. These quantities do not include replacement spares for intermediate replacement of parts required by abuse or misuse of the equipment. The recommended quantities are based on the ratio of spare parts sold for each unit during a one-year period of time. The actual quantity required will vary from location to location.


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Figure 1 64080 3” Inline Valve


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TABLE 2.0 64124 4” Control Valve


Valve Option

Spares/10 Units/yr.

2 1E 27218-1 4” Sub-assembly flanged both ends 1 Standard - 220813 4” Housing, flanged both ends 1 Standard - 1G 47218-2 4” Sub-assembly, flanged inlet, Victaulic outlet 1 D - 220816 4”Housing, flanged inlet & Victaulic outlet 1 D - 1H 47218-3 4” Sub-assembly, victaulic inlet, flanged outlet 1 E - 220814 4”Housing, victaulic inlet & flanged outlet 1 E - 1J 47218-4 4” Sub-assembly, victaulic both ends 1 DE - 220815 4”Housing, victaulic inlet & outlet 1 DE - 2-3 Left intentionally blank 4 200754 Seal, Outer Piston 1 All 5 5 MS29513-155 O-ring 1 All 5 6 Left intentionally blank 7 LP51958-64 Screw 4 All - 8 NAS620C10L Washer 4 All - 15 MS29513-149 O-ring 1 All 5 16 MS29513-240 O-ring 1 All 5 9-14 &

17-23 47351-1 Piston Assembly 1 All -

9 38NST188 Nut 2 All - 10 GF960C616L Washer 2 All - 11 202334 Piston, Outer 1 All - 12 221608 Retainer 1 All - 13 203565 O-ring 1 All 5 14 221595 Seal, Shaft 1 All 5 17 221594 Guide 1 All - 17A NAS1351C04-4 Screw 6 All - 17B 5610-381-50 Washer, Teflon 1 All - 18 200757 Spring 1 All - 19 202290 Shaft 1 All - 20 5720-158-25 Washer, Bronze 2 All - 21 202291 Washer 1 All - 22 MS29513-012 O-ring 1 All 5 23 200759 Piston, Inner 1 All - 24 GF16997-32L Screw 4 All - Items 25A, 27A & 28A have been superseded by items 25, 27 & 28 25 222160 Housing, Seal 1 All - 25A 221307 Retainer, Housing, Seal 1 All - 26 MS29513-134 O-ring 2 All 10 27 222165 Seal, Inner Piston 2 All 5 27A 200758 Seal, Inner Piston 2 All 5 28 222161 Retainer, Seal 1 All - 28A MS29513-129 O-ring 2 All 5 29 205756-2 Housing, Check Valve 1 All - 30 MS29512-08 Gasket 1 All 5 31 MS29513-009 O-ring 1 All 5 32 205772 Check Valve 1 All - 33 200791 Spring 1 All - 34 220413 Control Screw 1 All - 35 220472 Spring 1 All - 36 5406-P-04 Plug 2 All (1 only on

Option B) -

37 206B-1 Valve, Trapped Pressure Relief 1 B - 38 40766 Adapter Assembly 1 C - 39 210420 Adapter 1 C - 40 82154 Gasket 1 C 5 41 210421 Bolt 8 C -


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Kit Number Description

KD64124-1 Kit - Contains the parts needed to overhaul the 64124 valve assembly – contains items 2-4, 2-5, 2-13, 2-14, 2-15, 2-16, 2-22, 2-26, 2-27, 2-30 and 2-31.

KD64124-2 Kit – Contains Piston Assembly 47351-1 for 4” valve– Contains items 2-9, 2-10, 2-11, 2-12, 2-13, 2-14, 2-17, 2-18, 2-19, 2-20, 2-21, 2-22 and 2-23.

KD64124-4 Kit – Contains the housing and retainer necessary to upgrade to the now standard seal cartridge design. Contains items – 2-25 and 2-28.

Notes:

1. All part numbers beginning with "GF" are interchangeable with those beginning with either "AN" or "MS". If the "GF" is followed by three numbers it is interchangeable with and "AN" part, otherwise it is interchangeable with an "MS" part of the same number.

2. The recommended spare parts shown above are the number required to support 10 units for one year or each overhaul whichever is sooner. These quantities do not include replacement spares for intermediate replacement of parts required by abuse or misuse of the equipment. The recommended quantities are based on the ratio of spare parts sold for each unit during a one-year period of time. The actual quantity required will vary from location to location.

Figure 2 64124 4” Inline Valve


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Table 3.0 Torque Specifications 64080 & 64124

Fig. Item Part Number Description Torque in.-lb.

1 or 2 24 GF16997-32L Screw(s) 18 ± 2 in.-lb. (21 ± 2 kg-cm) 1 or 2 9 38NST188 Nut(s) 195 ± 10 in.-lb. (225 ± 12 kg-cm)


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Figure 4

Outer Piston Seal Installation

Figure 5

Inner Piston Seal Run-In Tool AF42208-1

Aerospace GroupConveyance Systems Division 9650 Jeronimo RdIrvine, CA 92618 Ph (949) 452-9500 Fax (949) 452-9992

sm 64080

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