Hydrant Valve

Carter Ground Fueling Division
Argo-Tech Corporation
671 West 17th Street
Costa Mesa CA 92627
Ph (949) 764-2200 Fax (949) 631-2673
Email [email protected] www.argo-tech.com
SM60554
MAINTENANCE MANUAL
FOR CARTER
MODEL 60554
HYDRANT VALVE
Revised September 2006

Supersedes Issue June 2006
ASSOCIATED MANUALS
SM47076 - OPTION N INSTALLATION
SM60554 September 2006
TABLE OF CONTENTS
PAGE
1.0 INTRODUCTION ..........................................................................................................3

2.0 EQUIPMENT DESCRIPTION.......................................................................................3
3.0 TABLE OF OPTIONS & ORDERING INFORMATION .................................................4
4.0 SAFETY INSTRUCTIONS/PREVENTATIVE MAINTENANCE ....................................5
5.0 OPERATION ................................................................................................................7
6.0 DISASSEMBLY ............................................................................................................8
7.0 INSPECTION..............................................................................................................13
8.0 REASSEMBLY ...........................................................................................................18
9.0 TEST ..........................................................................................................................23
10.0 TROUBLESHOOTING................................................................................................24
11.0 ILLUSTRATED PARTS CATALOG ............................................................................25
FIGURE 1 - OPTIONS........................................................................................................27
FIGURE 2 - UPPER HALF & OPTIONS A & B...................................................................30
FIGURE 3 - 2-PIECE UPPER HALF ..................................................................................31
FIGURE 4 - LOWER HALF ASSEMBLY ............................................................................33
FIGURE 5 - LANYARD OPERATED PILOT VALVE ..........................................................35
FIGURE 6 - AIR OPERATED PILOT VALVES...................................................................37
FIGURE 7 - AIR/LANYARD OPERATED PILOT VALVE, OPTION F ................................39
FIGURE 8 - AIR/LANYARD OPERATED PILOT VALVE, OPTION U ................................41
FIGURE 9 - AIR/FUEL PILOT VALVE CONNECTOR ASSEMBLY OPTION..................43
2
MAINTENANCE, OVERHAUL & TEST INSTRUCTIONS

CARTER PART NUMBER 60554 HYDRANT VALVE
1.0 INTRODUCTION
This manual furnishes detailed instructions Note: The various items specified in this
covering the maintenance and overhaul of manual are referred to in parenthesis and
Carter Model 60554 Hydrant Valve, a indicate the figure number and item number
family of hydrant valves as described in a within that figure where the item appears.
later paragraph. A separate manual Example: Servicing Valve (4-3) is item 3
covers the two special versions of the found in Figure 4.
60554, 60554-2D (SM60554-2D) and
60554-3D (SM60554-3D).
2.0 EQUIPMENT DESCRIPTION

The Carter 60554 family of hydrant valves designed to mate a flat faced ANSI 150
starting with serial number 11161 has been lb, 4 inch pipe flange. The outer housing
qualified in accordance with the Third material is available in either of two grades
Edition of API 584. This version of the of ductile iron as explained below.
industry specification includes the updating
of the Second Edition and combines the Upper Housing Assembly -
requirements of the Institute of Petroleum functionally identical on all valves. The
Requirements to arrive at an industry wide standard upper housing assembly consists
specification. The main thrust of the Third of an aluminum base casting with a
Edition is to cover in more detail the break- replaceable stainless steel coupler
a-way capability of the combination connecting ring. Two grades of ductile iron
hydrant valve and coupler to improve safety material are available as options as noted
on the ramp. Specific tests were required below. In addition, the "S" option changes
of the combination of products to prove that the complete upper housing to stainless
the hydrant valve and couplers met these steel. The outlet connection in all cases is
requirements. Ask Carter for 3QTR60554 in accordance with API Bulletin 1584.
Test Report for the results of the tests on Pilot Valve - five different pilot valves
the Carter products. are utilized on all but Option X. Option
Older units (serial numbers under 11161) X is a new approach used where the
can be updated to meet the new major parts of the pilot valve is contained
requirements by using a kit noted later. on a hose mounted unit further simplifying
the in-pit valve. There are two versions of
The Carter 60554 family of hydrant valves the new on-hose pilot, air or fuel operated
is manufactured with a choice of five and air or fuel operated with manual
different pilot valve arrangements, lanyard override.
or air pressure operation, capable of
flowing in the fueling direction only, or with As previously mentioned, valves as
air pressure operation, capable of both options are available in two different
fueling and defueling operations and two grades of ductile iron and one is available
different dual air/lanyard pilots. The with a stainless steel upper housing. One
lanyard operated type valve is also version (60554-3D, not covered by this
available in two different grades of ductile manual) utilizes metric threaded fasteners
iron. All versions consist of three major to attach the Upper and Lower Housing
sections: Assemblies together.
Lower Housing Assembly - Various options are available to modify the

functionally identical on the valves that basic part number to customize the end
are capable of flow in the fueling direction item to meet various customers
only. The "J" option uses a different requirements. These options are explained
assembly. The inlet flange, in all cases, is in detail in paragraph 3.0 below.
3
3.0 TABLE OF OPTIONS & ORDERING INFORMATION

There are seven basic valves to which various modifications may be added by option letters as
shown in the table below. The six basic units are as follows:
60554D - Lanyard Operated Pilot Valve for manual on/off control. Valve allows flow in the fueling
direction only.
60554E - Air Operated Pilot Valve for deadman control. Valve allows flow in the fueling direction
only.
60554F - Dual Air and Lanyard Operated Pilot Valve for deadman control and manual on/off control
for use in small pit (12 or 13 dia.) only. Uni-directional only unless combined with option J.
60554J - Air Operated Pilot Valve for deadman control with defuel control to allow flow of fuel in
either fueling or defueling direction.
60554U Dual Air and Lanyard Operated Pilot Valve for deadman control and manual on/off control
for use in standard pits (18 or larger). Uni-directional only unless combined with option J.
60554-3D - Same as 60554D except material of outer housing is ductile iron per ASTM A395
(Special Order only). The Upper and Lower Valve Assemblies are fastened together with 15 metric
threaded screws instead of the normal 8 UNF threaded screws. (Replaced 60554-2D).
60554X Air or fuel operated valve with the operating portion of the pilot valve contained on a
mating unit located on the hose from the hydrant servicer.
TABLE OF OPTIONS
The following option letters may be combined with the above basic units to customize the valve to fit
specific installation requirements:
OPTION
LETTER DESCRIPTION
A Adds 10-mesh screen between upper & lower halves of unit (81557-10).
B Adds 20-mesh screen between upper & lower halves of unit (81557-20).
C Adds six-position product selection (44290).
G* Adds Spool Piece to convert inlet flange to mate with 6" 300-lb ASA Raised Face
Flange. This option is required to meet the IP Standard (44364). Resultant height of
valve is 18. (Special Order on 60554-2D & 3D).
H** Adds 4-mesh Stone Guard to inlet. Available only with "G" option above (43587).
K Adds Inlet Adapter Kit to basic unit to fit into Avery Hardoll 12" pit. (Some modification to
the Avery Hardoll mounting flange might be necessary). Can not be used with Options G,
H or L (44744).
L Adds Inlet Adapter Kit to basic unit to fit into Avery Hardoll 13" pit. (Some modification
to the Avery Hardoll mounting flange might be necessary). Can not be used with
Options G, H or K (44745).
M Adds Quick Disconnect air connection to pilot port. Available only with E, F or J basic
units only (44731).
N Adds adapter kit for installing unit into 12 or 13 Avery Hardol Pits with 3 ANSI
mounting flanges. Can not be used with Options G, H, K or L (47077).
P Adds 4 Spool Piece to convert inlet flange to mate with 6" 300-lb ASA Raised Face
Flange (47199). Resultant valve height is 16.0. (Special Order on 60554-2D & 3D).
Q Replaces standard 2-piece (aluminum/stainless steel) upper with one piece ductile iron
upper half (same as units previous to 2-piece units).(43214)
R Replaces standard 2-piece (aluminum/stainless steel) upper with ductile/stainless steel
2-piece upper half. (47203-2)
S Changes upper half housing to stainless steel (43214-4).
T Adds fusible plug to air pilot line. (47326) (Not available with Option X)
4
* This option may have been originally made under license by various Carter
distributors and for that reason may not be exactly the same, although physically
and functionally interchangeable.
** This option is not licensed to be made by any company except Carter and any
furnished should be original equipment. Failure during the extreme high flow
testing by API resulted with product made by a company other than the factory.
Example: 60554BDGH - 18 high IP Standard Unit with 6" inlet, manually operated
pilot valve, stone guard & optional 20-mesh screen.
4.0 SAFETY INSTRUCTIONS/PREVENTATIVE MAINTENANCE

4.1 SERVICING VALVE UTILIZATION - The Assembly (2-6) to bleed. If the flow from
unit incorporates a servicing control the Equalization Poppet (2-13) reduces to
valve designed to allow the Upper a matter of leakage as differentiated from
Housing Assembly and/or the Pilot continuous flow under pressure, it is safe
Valve to be removed while the inlet of to proceed.
the unit is under pressure. See caution
below.
CAUTION!
The Lower Housing Assembly consists
If the flow from the Equalization Poppet (2-
of a pressure overbalanced piston
13) is steady and under pressure, do not
assembly that shuts off the main flow
continue to remove the Upper Housing
path. The slipper type seals utilized on
Assembly (2-6).
the piston are not absolutely zero leak
seals and an increase in leakage past
these seals is anticipated with age. If On all but Option X - Remove
the leakage increases too much, the the Pilot Valve (1-D, 1-E, 1-F, 1-J or 1-
piston will no longer stay closed. It is U) and wait for at least one minute while
therefore recommended that the hydrant checking the leakage out of the hole
not be maintained by use of the from which the Pilot Valve (1-D, 1-E, 1-
servicing valve on a regular basis and F, 1-J or 1-U) or the quick disconnect
when it is used, the following procedure was mounted. If the leakage does not
should be followed to reduce the appear to be under pressure proceed
possibility of a major spillage of fuel: with the next step.
On Option X Use a diameter
CAUTION! plastic rod to depress the valve stem
located within the quick disconnect fitting
It is not recommended that this procedure
and wait for at least one minute while
be utilized, except in an emergency
checking for leakage. If the leakage does
condition. The use of this valve does
not appear to be under pressure proceed
pose a possible hazard if not correctly
with the next step.
accomplished and the valve is not in
good working order. Remove the Screws (2-3 & 2-5)
attaching the Upper Half Assembly (2-6)
If an inlet butterfly valve is available, close and Lower Half Assembly (5-1).
it to reduce the inlet pressure from the
hydrant system. CAUTION!
Close the Servicing Valve (4-3) As long as the hydrant system pressure is
securely, by hand. The seal on this valve on do not attempt to remove the Lower
could be damaged if a wrench is utilized. Housing Assembly (5-1) from the inlet
No threads on the Stem (4-3) should be pipe or loosen the Servicing Valve (4-3).
visible when the valve is fully seated.
Manually depress the pressure 4.2 HOT HYDRANT - Refer to paragraph 7.1.2
Equalization Poppet (2-13) and allow the for the testing procedure to determine
pressure inside the Upper Housing
5
whether a hydrant is hot or not. This The gauge is shown in Figure A below.
preventative maintenance procedure should
be conducted after one year of service and
every six months thereafter for maximum
benefit.
4.3 OUTLET SAFETY INSPECTION - The

60554 is designed to meet the break a-way
requirements of the 3rd Edition of API 1584.
To assure that the unit will continue to meet
these requirements it is necessary to Figure A 60554ST1 Wear Gauge
annually inspect the outlet configuration to
assure that it meets the dimensions that The gauge has two sides, A to check the
allows it to be within specification. outer diameter and B to check the angular
underside wear surface of the outlet
configuration. This gauge is meant to
WEAR GAUGE NOW AVAILABLE! determine whether the outlet will continue to
meet the break a-way requirements of API
A new gauge to check the wear on the outlet 1584 if the mating coupler is a Carter
connection of the 60554 is now available as unit and it is also within the wear
part number 60554ST1. It is a no-go tolerance of it wear gauge 61362. See the
gauge in that it checks the two critical appropriate Coupler manual for instructions
surfaces of the API interface for non- on how to use the 61362.
conformance to API 1584 and safe usage
with any Carter coupler. First attempt to pass side A across the
hydrant outlet in at least 4 places
approximately 45 apart. If the gauge can
be passed across the outlet the outlet is
worn and needs replacing.
Second, attempt to pass side B across the

hydrant outlet in at least 4 places
approximately 45 apart. If the gauge can
successfully be passed across the outlet
the gripping surface is worn and the outlet
needs replacing.
6
5.0 OPERATION
Figure A reflects a lanyard

operated pilot valve shown
in the open position. The
operation of the Hydrant
Valve, whether the pilot is
lanyard, air operated or new
Option X is identical.
Figure A
Figure B reflects the same

hydrant valve with the air
pilot in a closed position.
The only differences
between the two units are in
the operating mechanism
that supplies the power to
open and close the pilot
valve. In the air operated
pilot, the closing lanyard and
opening latching mechanisms
are replaced with an air
operated piston. When Option
X is present the air pilot is
separated with the piston
operator as a part on the
hose to the valve.
Figure B
7
Servicing Valve Closed Pilot Valve Closed

Pilot Valve Open or Closed Servicing Valve Open
The closing of the Servicing Valve (4-3) has the Pulling the lanyard, or depleting the air supplied to
same affect as closing the Pilot Valve (1-D, 1-E, their respective pilots, will allow the spring loaded
1-F or 1-J). That is, the flow passage from the pilot poppet to close. (Depleting the air supply
piston chamber to the downstream side of the can be accomplished by activating the deadman
piston is blocked. The piston chamber pressure control or in the case of an Air/Lanyard Pilot
begins to equalize to the inlet pressure (P1) pulling the lanyard will release the air pressure.
through the check valve. The piston area is The lanyard is meant for an emergency closure
greater than the effective seal area, hence the only and is not meant to be used at each
unbalance of forces caused by the equal refueling.) This action blocks off the venting of the
pressure, plus the spring, will cause the valve to piston chamber to the lower pressure area
stay closed. downstream. The piston chamber begins to
equalize to the inlet pressure (P1) through the
Pilot Valve Open check valve. The piston area is greater than the
Servicing Valve Open effective seal area, hence the unbalance of forces
caused by the equal pressure plus the spring will
The open pilot valve allows the continuous cause the piston to begin to close. As the piston
passageway from the main piston chamber and moves toward the closed position, the piston
from the closing control orifice. The piston chamber volume increases and must be filled
chamber is vented through an opening control through the two series orifices. The primary
orifice and the open Servicing valve to a point in orifice is considerably larger than the secondary
the Lower Valve Half. The pressure (P2) at this (slot). During the initial and majority of the travel
point is less than the inlet pressure (P1). The of the piston, the primary orifice is fully exposed to
piston chamber pressure is also maintained at P2 the inlet pressure, hence the rate of closure is
causing an unbalance of forces on the piston. controlled by this orifice.
The inlet pressure force is greater than the
combined piston pressure force plus the spring When the piston moves far enough closed to
force hence the valve will open to allow flow. This cover the primary orifice, the secondary (smaller)
is assuming that the outlet adapter poppet in the orifice begins to control the closure rate. Hence
Upper Valve Half has been opened by a Coupler. the valve begins to close relatively rapidly and
then slows down as it nears its closed position.
The pilot poppet is maintained in the open The relative size and locations of these two
position by one of two methods: orifices allows the valve to close to provide a
Lanyard operated pilot - The pilot is opened minimum of overshoot and yet limit the surge
by the pull of the "T" handle located on the top of pressure shock, on closing, and still maintain a
the pilot valve. When it is pulled upward, the closure rate in accordance with applicable
spring loaded latch attached to the lanyard pivots international specifications.
to lock the pilot into the open position. On "J" Defueling options the pilot valve is
Air or Air/Lanyard operated pilot - Air manually held closed by the thumb screw to allow
pressure applied to the pilot piston will maintain defueling flow. Pressure supplied to the hydrant
the pilot in the open position until the pressure valve outlet will cause the piston to open (as long
has been depleted (by release of deadman). as the pilot valve is manually held in the closed
position). The overbalance of areas between the
outer diameter of the piston versus the main
piston seal area caused the outlet pressure to
open the piston to allow defueling flow.
6.0 DISASSEMBLY
This disassembly procedure assumes although the Gasket (1-11) used
that the valve is located within a shop between the two parts (Valve and
area where there is the capability of Spool) should be replaced at each
supplying the necessary tools. It is also removal of the unit from the pit. The
assumed that options G, P or H are not same goes for spool pieces used as
removed from the pit for maintenance, Options K and L (1-K & 1-L).
8
small bladed screwdriver into the hole in

Note: the Spring Guide (9-9) and pry the spring
guide from the part. This allows one to
The valve will be full of fuel and provisions for remove the other parts within and to
draining into a safe container should be made replace the stem if necessary.
prior to beginning to work on the unit.
6.5 Remove Screws (2-3 & 2-5) and Washers
(2-4). Note that Screw (2-5) is shorter than
6.1 Place the unit in a container sufficiently
Screws (2-3). It should be noted that it
large enough to contain a minimum of 5
was installed in the hole to the left of the
gallons (19 l) of fuel. Remove the Cover
Pilot Valve (1-D, 1-E, 1-F, 1-J or 1-U) when
Assy (2-23). Push the Adapter Poppet (2-
facing the unit with the Pilot Valve (1-D, 1-
11) open and hold it open with a flexible
E, 1-F, 1-J or 1-U) directly in the center.
plastic rod, or another non-marring item,
Note that on newer units this shorter Screw
to allow the unit to drain. Hint: A scrap
(2-5) is made of stainless steel, for ease of
23620 Rod used in Carter 60427 Nozzle identification only, instead of the normal
is suitable for this job. cadmium plated Screws (2-3).
6.2 Remove the Servicing Valve (4-3) and set 6.6 Using a thin, wide blade screwdriver,
aside. gently pry the Upper Half Assy (2-6) from
the Lower Half Assy (4-1). Be careful not
6.3 Turn the unit over onto its outlet, being
to damage the epoxy coating. Remove
sure to place it on a surface that will not
and discard O-ring (2-22). Set the Lower
damage the outlet surfaces. Grasp the
Half Assy (4-1) aside.
inlet flange and apply pressure to the
Piston (4-18) to push it open sufficiently to 6.7 Remove Strainer (2-21), if present, from
insert a flexible plastic rod to keep the unit. Set it aside.
piston open as with the Adapter Poppet
(2-11) above. Turn the valve over a few 6.8 Upper Half Assy (2-6) - Remove the
times to allow the trapped fuel to drain. plastic rod holding the Poppet (2-11) open
The rod can then be removed to close the and install the Cover Assy (2-23) to
Piston (4-18). protect the Upper Half Assy (2-6). Turn
the unit over onto the Cover Assy (2-23).
6.4 Pilot Valve/Pilot Valve Connector Removal
6.8.1 While pushing downward on Poppet
6.4.1 Pilot Valve - Remove Screws (5-29 , 6-18, Retainer (2-19), using a thin blade
7-18 or 8-18) and Washers (5-28 , 6-19, screwdriver, remove Retainer Ring (2-20)
7-19 or 8-19). Grasp the Pilot Valve ( 1- from Upper Housing (2-7). Slowly release
D, 1-E, 1-F, 1-J or 1-U) and twist back and downward pressure on Poppet Retainer
forth while applying a force away from the (2-19) to remove it, Spring (2-18) and
unit to remove the pilot. While removing Poppet Assy (2-8).
the Pilot Valve ( 1-D, 1-E, 1-F, 1-J or 1-U)
be sure to maintain a straight upward 6.8.2 Newer valves may have a 2-piece upper
pressure to prevent causing a binding of housing. This is easily determined by the
the parts contained within the Lower aluminum (no epoxy coating) cast upper
Housing Assy (4-10). Some of these parts housing and the stainless steel adapter
could be damaged if a binding during ring. If the upper housing is epoxy coated
disassembly occurs. Lay the Pilot Valve or all stainless steel no further disassembly
(1-D, 1-E, 1-F, 1-J or 1-U) aside for now. is possible. If it is the 2-piece upper it is
not necessary to disassemble the part
6.4.2 Pilot Valve Connector Assembly (Option farther unless there is a leak at the joint
X) Remove the two Screws (9-5) and between the Ring (3-4) and the Housing
Washers (9-6) to remove Connector (9-2). (3-2), then the O-ring (3-3) must be
Remove and discard O-rings (9-3) and (9- replaced. Another reason for further dis-
4). If it is necessary to remove the Valve assembly would be to replace the Ring (3-
Stem Assembly (9-7) special tool 4) due to severe denting which can cause
T221790 will be needed to unscrew it leakage when the coupler is attached.
from the lower housing. If removed
discard O-ring (9-8). If removed the Stem
(9-11) may be replaced by first placing a
9
Piston Retainer (4-16). The later versions

NOTE: utilize six. This change was made
necessary on a similar valve, model 61654
If the O-ring (3-3) is being replaced it will with a six inch ANSI flange. On the model
be necessary to heat the assembly to 60554, the Piston Retainer (4-16) is
300F (150 C) for at least one-half hour retained in place by the mating pipe flange
before trying to remove the Screws (3-5). hence the mandatory use of six screws is
Trying to remove them at room not necessary. However, if there are six
temperature may result in twisting them present, all six should be replaced. Note: If
off due to the use of Locktite to retain Screws (4-15) are difficult to remove, an
them in place. If the Ring (3-4) is being impact wrench may be necessary to
replaced then damaging the screws is of prevent damage to the Phillips recesses of
no concern since the ring will be the Screws (4-15). Also note: Normally,
discarded along with the screws. the main Spring (4-26) will be strong
enough to force the Piston Retainer (4-16)
Then remove the Screws (3-5) and out of the unit. If not, use a thin blade
Washers (3-6) from the inside of the unit. screwdriver to carefully pry out Piston
Carefully pry the stainless steel Ring (3-4) Retainer (4-16). Remove and discard O-
from the Housing (3-2). Remove and Ring (4-17).
discard O-ring (3-3).
6.9.1 Remove Piston Assy (4-18 to 4-21),
6.8.3 Using a thin blade screwdriver, carefully Spring (4-26), Washer (4-27) and Seal (4-
pry an end of the Retaining Ring (2-17) 28). Discard Seal (4-28). Remove
and remove it from its groove. Disassemble Screws (4-19), Seal Retainer (4-20) and
Poppet Assy (2-8) removing the various Seal (4-21). Discard Seal (4-21). Using
parts. Remove Seal Ring (2-9) from Seal an o-ring pick, carefully remove and
(2-10) and discard Seal (2-10). Remove discard O-Ring (4-22) and Slipper Seal
and discard Seal (2-12). (4-23) from Piston (4-18).
6.8.4 If present and the valve is the obsolete 6.9.2 Using an o-ring pick, carefully remove
style that utilized bosses cast onto the Piston Seal (4-25) and O-Ring (4-24) and
Upper Housing (2-7), there is no need to discard both.
disassemble the product selection part of
the Upper Half Assy (2-6) unless parts 6.9.3 Check to see if the Shaft (4-12) is loose in
need replacing due to missing or damaged the Lower Housing (4-11) only, do not
parts. On newer valves, these bosses attempt to remove Screw (4-14), Washer
were removed and the product selection (4-13) or Shaft (4-12) from Lower Housing
feature is achieved by the addition of the (4-11). The Shaft (4-12) is press fitted into
Product Selection Ring Assy (1-C). This the Lower Housing (4-11) and neither part
ring is attached to the unit by using four is available as a replaceable spare part. If
extra long Bolts (1-5) and Standoffs (1-2). it is necessary to replace the Shaft (4-12),
It is then necessary to disassemble the it is necessary to replace the Housing
Product Selection Assy (1-C) from the unit Assy (4-10) as a complete unit.
during disassembly of the valve. On older 6.9.4 Using an appropriately sized wide blade
versions of the newer valves, the Ring (1- screwdriver, remove the Cage (5-18 , 6-2,
1) holding the product selection studs is a 7-2 or 8-2) from Lower Housing (4-11) by
solid one piece ring. On newer valves the unscrewing counter clockwise. Remove
ring is composed of four equally thick and discard O-Ring (5-1, 6-11, 7-11 or 8-
stamped Rings (1-1). The older units utilize 11) from Cage (5-18 , 6-2, 7-2 or 8-2).
one piece product selection studs while the
newer units utilize standard Bolts (1-3) and 6.9.5 It is not necessary to remove the Orifice
a stack of Washers (1-4 & 1-6). If (4-29) located in one of the internal holes
replacement of either the older ring or the visible through the Servicing Valve (4-3)
studs is required, utilize the newer port. Using shop air pressure, blow air
replacement parts. through the opening to clear the Orifice
(4-29). If the air does not flow easily
6.9 Lower Half Assy - Turn Lower Half Assy (4- through the orifice out through the inner
1) over to expose the inlet flange. Remove part of the Lower Housing (4-11), the
Screws (4-15). Early versions of the unit Orifice (4-29) may be plugged. In that
utilized only two Screws (4-15) to retain the
10
case, it will be necessary to remove the "floating" design for more reliable
Orifice (4-29) and either clean it or operation. Since the older parts have been
replace it. out of production for many years, it may be
necessary to consider replacing the entire
6.10 Operrated Pilot Valve (1-E) - In the history Pilot Valve 42846 with Pilot Valve 44721.
of the 60554 Hydrant Valve there have
been three different Pilot Valves utilized: It is not necessary to remove the Air
Quick Disconnect or Fusible Plug (1-M or
Current (1991 & later) production unit, 1-T if furnished as such) from the unit
part number 44721, utilizes the same unless it is necessary to replace the unit.
Housing (6-1) and Piston (6-14) as is used
on the Defueling Pilot Valve (1-J). A Spacer Compress Spring (6-7) with Spring
(6-17) is added on the Shaft (6-16) between Retainer (6-6) sufficiently to remove Pin
the Housing (6-1) and the Piston (6-14). (6-4). This allows the removal of Poppet
The change to this unit was made to (6-3). Slide Spring (6-7) off of Shaft (6-16).
standardize on production parts between Unscrew Adapter (6-5) from Shaft (6-16).
the pilot valves used on both Options E and Slide O-Ring Retainer (6-8) off of Shaft (6-
J. The only way to tell the obsolete pilot 16). Carefully pick out O-Ring (6-9) from
valve apart from the current production unit Housing (6-1) and discard. Remove and
is to disassemble the unit and check for the discard O-Ring (6-10). Remove Cover (6-
presence of the Spacer (6-17) or to look at 12) and Spring (6-13). Push Piston (6-14)
the bottom of the Piston (6-14) chamber of out of Housing (6-1). Remove Spacer (6-
the Housing (6-1). If the chamber bottom is 17). It is not necessary to unscrew Shaft
flat bottomed as opposed to a conical (6-16) from Piston (6-14) unless either part
bottomed, the pilot valve is of current is damaged and must be replaced.
vintage. If the bottom is conical the pilot Remove and discard Bal Seal (6-15) from
valve is an old style 44247. Piston (6-14).
6.11 Air Operated Pilot (1-E), 44247 (Obsolete) -
On newer valves (after first quarter Follow above procedure in paragraph 6.10
2000) the Housing (6-1) may be changed except the following parts are different:
to provide better production economics.
The newer valves may use the housing Housing (Obsolete) instead of Housing
from the dual air/lanyard operated pilot (6-1)
valves with a Plug (6-27) to fill in the extra
air port. This also gives the option to Piston (Obsolete) instead of Piston (6-14).
install the air connection in either of the 6.12 Air Operated Pilot (Defueling type) (1-J) -
available ports to move the connection Newer valves (those received after the
farther away from possible damage from first quarter of 2000) may have a different
the dropping of the coupler onto the valve. defuel control screw. The Screw (6-23)
was shortened and made with a larger
Previous generation Pilot Valve (1-E) - thread size to help prevent operators from
As mentioned above, this unit has a conical bending it when the coupler is dropped
bottomed piston chamber. The Piston (6- onto the hydrant. This made it necessary
14) is also different. The older Piston (6-14) also to change the Cover (6-22) and Pin
will not work in the newer pilot valve. (6-24) to suit. Ordering any of the older
Should an older Housing (6-1) be needed parts will automatically be entered as the
for replacement, it will be necessary to also pre-assembled Screw Assembly (6-21). In
procure a new Piston (6-14), Spacer (6-17) addition the Housing (6-1) was changed
and the new Housing (6-1). to provide better production economics.
The newer valves may use the housing
First generation Pilot Valve (1-E) - This from the dual air/lanyard operated pilot
Pilot Valve, part number 42846, utilized valves with a Plug (6-27) to fill in the extra
some of the same parts as are currently air port. This also gives the option to
utilized. However, there are major install the air connection in either of the
differences. One of these differences can available ports to move the connection
be upgraded to current production by farther away from possible damage from
utilizing kit 2KD42836, provided the the dropping of the coupler onto the valve.
existing Cage (6-2) is still usable. This kit
replaces the fixed pilot seal poppet with a
11
The disassembly procedure is the same suitably padded vise and pull Pins (5-8)
as in paragraph 6.10 except for the with pliers.
following changes and the addition of
several parts as noted: If necessary to replace parts, using a .187
(4.750 mm) dia. drift pin, remove Pin (5-7)
Cover Assy (6-21) instead of (6-12). from Handle (5-6) and Latch Spool (5-4).
Note on older valves the hole in the
Additional parts include Defuel Control Handle (5-6) for this Pin (5-7) is on center.
Screw (6-23), Pin (6-24), Wave Washers Newer valves have the hole to one side.
(6-25), Washers (6-26) between the Even newer valves have a ball attached
Wave Washers (6-25) and Wear Plate (6- to the Handle (5-6) to prevent possible
20) between the Piston (6-14) and the interference between the Handle (5-6)
screw on the Cover (6-22). Cover (6-22) and the mating coupler bumper. Do not
need not be disassembled unless some try to remove the ball from the end of the
part is damaged and needs replacing. Handle (5-6) unless it is loose and needs
6.13 Lanyard Operated Pilot (1-D) - In the history replacing.
of the 60554D Lanyard Operated Valve, 6.14 Air/Lanyard Operated Pilot (1-F) - It is not
there have been two different Lanyard necessary to remove the Air Quick
Operated Pilots, 42836 and 44248. These Disconnect (1-M if furnished as such) or
units can be identified as follows: the Fusible Link (1-T) from the unit unless
it is necessary to replace the unit.
The current design unit incorporates a
floating pilot poppet design to provide for Compress Spring (7-7) with Spring Retainer
more reliable operation. The Poppet (5-22) (7-6) sufficiently to remove Pin (7-4). This
has a bonded on rubber seal. The Cage (5- allows the removal of Poppet (7-3). Slide
18) now used is interchangeable with the Spring (7-7) off of Shaft (7-16). Unscrew
older cage. In addition, when the valves Adapter (7-5) from Shaft (7-16). Slide O-
leave the factory, the Cable Clamp (5-15) Ring Retainer (7-8) off of Shaft (7-16).
utilized is crimped onto the Cable (5-10). Carefully pick out O-Ring (7-9) from Housing
(7-1) and discard. Remove and discard O-
The first generation Lanyard Ring (7-10). Remove Cover (7-12) and
Operated Pilot Valve, 42836, has the fixed Spring (7-13). Push Piston (7-14) out of
pilot poppet design and utilizes a two piece Housing (7-1). Remove Spacer (7-17). It is
screwed together Cable Clamp (5-15A). not necessary to unscrew Shaft (7-16) from
The pilot poppet seal is replaceable and is Piston (7-14) unless either part is damaged
held in place by a screw. and must be replaced. Remove and
discard Bal Seal (7-15) from Piston (7-14).
Compress Spring (5-24) with Spring
Retainer (5-23) sufficiently to remove Pin Remove Valve Assembly (7-20) from
(5-20). This allows the removal of Poppet Housing (7-1) to repair parts within
(5-22). Slide Spring (5-24) off of Shaft (5- Valve Assembly (7-20). Using a drift pin
16). Unscrew Adapter (5-21) from Shaft remove Pins (7-21) being sure to
(5-16). Slide O-Ring Retainer (5-25) off of adequately support the Valve Assembly
Shaft (5-16). Remove Pilot Retainer (5- (7-20) so as not to damage it.
27) and carefully pick out O-Ring (5-26) Disassemble Connector (7-22) from
and discard. Remove and discard O-Ring Seat (7-23). Items (7-24) through (7-28)
(5-19). may be removed for replacement as
required. Unscrew Guide (7-29) from
Push Latch Spool (5-4) to force the Shaft
Connector (7-22). Items (7-30) through
(5-16) out of Housing (5-2) sufficiently to
(7-33) may be removed for repair or
remove Pin (5-17). If the pilot latching
replacement. Do not remove Ring (7-35)
mechanism requires servicing, cut the
unless replacement of the Reset Ring
Cable Assy (5-10) or Clamp (5-15) after
(7-36) or Guide (7-29) is necessary. Do
removing Hose (5-13) and Clamp (5-14).
not remove Cable Assembly (7-37)
Cable Assy (5-10) can then be pulled
unless it is necessary to repair or
back through Latch Bracket (5-9) to allow
replace it. If necessary, cut Cable (7-40)
removal of Spring (5-12) and Latch Stop
after removal of Clamp (7-39) and Hose
(5-11). If the Latch Bracket (5-9) is to be
(7-41) to repair. Cable Retainer (7-33)
replaced, mount Housing (5-2) in a
12
can also be removed from the cut cable Using a drift pin remove Pin (8-22) being
assembly. sure to adequately support the Valve
Assembly (8-21) so as not to damage it.
6.15 Air/Lanyard Operated Pilot (1-U) - It is not This frees up several parts attached by
necessary to remove the Air Quick means of the Pin (8-22). Remove Pin (8-26)
Disconnect (1-M if furnished as such) or as above. Unscrew Guide (8-30) from
the Fusible Link (1-T)from the unit unless Connector (8-23). Items (8-31) through (8-
it is necessary to replace the unit. 34) may be removed for repair or
Compress Spring (8-7) with Spring replacement. Do not remove Ring (8-36)
Retainer (8-6) sufficiently to remove Pin (8- unless replacement of the Reset Ring (8-
4). This allows the removal of Poppet (8- 37) or Guide (8-30) is necessary. Do not
3). Slide Spring (8-7) off of Shaft (8-16). remove Cable Assembly (8-38) unless it is
Unscrew Adapter (8-5) from Shaft (8-16). necessary to repair or replace it. If
Slide O-Ring Retainer (8-8) off of Shaft (8- necessary, cut Cable (8-41) after removal
16). Carefully pick out O-Ring (8-9) from of Clamp (8-40) and Hose (8-42) to repair.
Housing (8-1) and discard. Remove and Cable Retainer (8-34) can also be removed
discard O-Ring (8-10). Remove Cover (8- from the cut cable assembly.
12) and Spring (8-13). Push Piston (8-14) 6.16 Servicing Valve (4-3) - Carefully using a
out of Housing (8-1). Remove Spacer (8- .156 inch (3.960 mm) drift pin, remove Pin
17). It is not necessary to unscrew Shaft (4-7). Remove Stem (4-6) from Poppet
(8-16) from Piston (8-14) unless either part Retainer (4-8). Remove and discard O-
is damaged and must be replaced. Ring (4-9) and Gasket (4-2). If Poppet (4-
Remove and discard Bal Seal (8-15) from 4) does not need replacement, do not
Piston (8-14). disassemble further. If necessary, using
Remove Air Bleed Valve Assembly (8-21) snap ring pliers, remove Ring (4-5) to
by removing the three Screws (8-20) and replace Poppet (4-4).
pulling Valve Assembly (8-21) from
Housing (8-1).
7.0 INSPECTION
7.1 PERIODIC INSPECTIONS system will quickly be apparent by the
expelling of a fuel mist out of the exhaust of
The inspections listed in this section should the deadman valve. This is not a safe
be conducted on a periodic basis, the situation around hot jet engines. Air
frequency of which should be no less than operated hydrant valves are not the primary
that mentioned in each section. The time source of the problem, just a possibility.
between testing should be tailored to fit the Leakage of fuel into the air system can
particular operation and age of the system. occur at any of the air-fuel interface points.
7.1.1 Fuel-in-the-air Check (applicable to all These are normally found in either the line
Options but D and X) - It is recommended mounted pressure control valves, hydrant
that this inspection procedure be couplers, float operated water sump control
conducted initially on new units after one valves or at the hydrant valve. Some of
year of operating and then each six these types of components, Carter 60700-1
months thereafter. Hydrant Coupler and 61024 Line Mounted
Pressure Control Valve, can be eliminated
Air operated hydrant valves are one from consideration since they have a vent
possible source of contamination when fuel between the air to fuel interface. If the fuel
leaks into the air systems. (If Option X is seal leaks on these units, it results in an
being used and there is fuel leaking into the external leakage out of the vent point, not
air system, the culprit may be in the 64230 into the air system.
or 64231 Pilot located on the hydrant
servicer hose). Many of the standard air 60554E, 60554J, 60554F and 60554U
components used within a refueling system Hydrant Valves utilize air operated pilot
are not necessarily fuel resistant, hence the valves with an air-to-fuel interface seal that
results can be costly and time consuming. is not vented, hence are candidates for fuel
In addition, fuel contamination in the air to the air system leakage with time.
13
Finding fuel in the air pilot's air chamber is allowed to close by the opening and
not conclusive that the air pilot is the closing of a mating coupler. A pressure
leakage source. However, every air pilot equalization valve is contained within the
that is leaking will have the symptom of poppet. This allows the trapped pressure
fuel in its operating air cavity and quick in the upper chamber of the valve to be
disconnect fitting (if so fitted). bled into the hydrant coupler when
extending the poppet to the open position.
The most obvious evidence that the air
pilot is responsible for air system Inlet Shutoff Valve (Isolation Valve in
contamination is steady flow (or weapage) the terms of the IP) - A spring loaded piston
of fuel emitting from the quick disconnect valve whose chamber is connected to the
fitting that is mounted to the air pilot. This inlet of the hydrant valve via an orifice and
confirmation will be made possible only if to the outlet through the servicing and pilot
the fitting is specifically designed to allow valves. Its function is to control opening
air to bleed from within the air pilot's air and closing times and to present a means
cavity. If the quick disconnect fitting is full for shutting off flow at the end of a refueling
of fuel, but leakage flow, as described operation, either by means of a lanyard or
above, is not obvious, then the following air operated pilot valve.
procedure can be used to confirm that the
air pilot is responsible for the leakage. Pilot Valve or the Valve Connector
Assembly (on Option X) - Either the
Remove the quick disconnect fitting and Valve Stem Assembly on Option X or a
dry the interior of the air cavity and fitting lanyard or air operated valve that controls
with a blast of clean, dry air. Perfection in the outlet bleed path from the Inlet Shutoff
this is not required, but closely examine Valve to the chamber between the Inlet
and mentally record the condition of the Shutoff Valve and the Outlet Adapter.
air cavity after cleaning for comparison as
noted below. Servicing Valve - A mechanical valve
located in series with the Pilot Valve
Refit the quick disconnect fitting. Establish (between the Inlet Shutoff Valve and the
full hydrant system pressure to the Pilot Valve). It is designed to keep the
hydrant's inlet. Using a clean, dry source Inlet Shutoff Valve in the closed position
of air, which is set to the same pressure while allowing the changing of the upper
used during normal operation of the air half of the valve (Outlet Adapter) including
pilot, apply and then remove the air the Pilot Valve.
pressure, cyclically, thirty (30) times (one
to two seconds on, then one to two Within the above sections of the hydrant
seconds off). When completed, remove valve there are various seals that prevent
the air fitting and inspect the air cavity leakage between the elements. In a valve
again. Any accumulation of fuel, not that is in good mechanical condition, the
logically associated with residual moisture Inlet Shutoff Valve and Pilot Valve
available in the air cavity, indicates that combine to keep the chamber between
the air pilot is responsible for air system the Inlet Shutoff Valve and the Outlet
contamination. Replace this air pilot with a Adapter at a lower than inlet pressure.
new or rebuilt air pilot. Overhaul of the air This is only possible, theoretically, if there
pilot while in the pit is not recommended. is zero leakage past the piston and Pilot
Valve seals. Any leakage, with the
If no significant fuel is found in the air passage of time, will allow this chamber to
chamber after the above investigation, it increase to inlet pressure. Fuel is not
can be assumed that the residual fuel compressible, hence a very small amount
previously seen in the air chamber came of leakage will raise the pressure in this
from another source (coupler or in line chamber to inlet. This does not mean that
valve). a hydrant valve is always "hot". If the
leakage rate past the appropriate seals is
7.1.2 "Hot Hydrant" Check - A Carter hydrant
greater than the amount of flow possible
valve consists of four major components all
through the pressure equalization valve
contained within a single valve element:
(at the time the coupler is attached and
begins to be opened) then the valve is
Outlet Adapter - A spring loaded "hot". In other words, the equalization
poppet valve that is manually opened and valve's capacity is insufficient to reduce
14
the pressure in this chamber during the from occurring. The fixing of the hot
coupler opening operation. hydrant valves would also make the
refueling operation easier and reduce,
WHAT PROBLEMS ARE CAUSED BY significantly, the coupler maintenance
HOT HYDRANTS? - Two major problems, costs.
not readily apparent, are caused or are
potentially caused by hot hydrants. TESTING PROCEDURES - It is
recommended that all new hydrant valves
Hot hydrant valves make the opening be tested after one year of service and at
of the hydrant coupler more difficult. The lease twice each year thereafter and any
hydrant valve has a poppet area, against indicated hot hydrant valves be removed
which pressure reacts, of approximately for maintenance immediately. The test
12.6 square inches. If the pressure against procedure recommended is the same for
which this poppet must be opened is a lanyard or air operated unit.
reduced appropriately by the pressure
equalization valve to about 20 psi, the Equipment Required - 61525E Coupler
opening force that must be generated by with pressure sense port in the elbow and
the coupler mechanism is only 252 the outlet plugged or a standard 61525 (any
pounds. If, on the other hand, the valve is outlet thread) with a small (3/8") port in the
hot and the inlet pressure is as much as outlet plug. A 60 psi air or nitrogen pressure
150 psi, the opening force must be 1,890 source (for air operated valves only); a
pounds. Under normal pressure conditions, short length of 3/8" plastic tubing or hose
it is relatively easy to open a valve against attached to the pressure sense or outlet
20 psi with the application of approximately port, a manual valve in the hose or tube; a
30 pounds force applied to the coupler 1000 cc beaker; and a plastic 2 gallon
handle (mechanical advantage reduces the bucket. (Note if a metal bucket is used,
force required). If the pressure is check with your company manual about
increased, by a hot hydrant, to 150 psi, the electrical bonding of the bucket to the
force necessarily applied to the coupler coupler before proceeding.)
handle is increased to 225 pounds. This is
outside of the realm of an average refueler Inlet Piston Valve Seals Test - Attach
so he will use his foot and force the handle the above test coupler to the test hydrant
to the open position. This tends to over valve with the coupler of the small shutoff
stress the coupler mechanism resulting in valve open to the bucket and open the
a premature failure condition, hence hydrant valve by pulling the T handle of
expensive, unnecessary maintenance Option D or by applying 60 psi air pressure
costs. to the pilot port of Options E or J. Allow the
hydrant valve and coupler to be bled of air.
A hot hydrant valve, caused by a Close the servicing valve of the test
failed Pilot (including the Valve Stem hydrant. Allow the leakage, if any, from the
Assembly (9-7) on Option X) or Inlet outlet to stabilize for about 30 seconds,
Shutoff Valve can be a potential major spill, then measure the leakage for at least 30
with the possibility of a fire. A recent seconds. The amount of leakage caught in
incident, with a competitors hydrant valve, the 30 seconds should not exceed 250 cc.
resulted in a major spill. The coupler was If it does, the hydrant valve should be
knocked off a functioning hydrant valve by tagged for removal and overhaul.
a baggage cart. The Outlet Adapter
Poppet stuck open and the Inlet Shutoff Pilot Valve, Valve Stem Assembly on
Valve failed to close because of a non- Option X & Servicing Valve Seals Test -
functioning air operated pilot, even though Close the pilot valve (pull the lanyard on
the air hose to the unit was also severed. Option D, remove the air pressure from
The result was a fairly major spill and Options E, F or J) or on Option X do not
luckily no fire. The failure was caused by connect the hydrant hose from the service
the fact that the Pilot Valve's poppet, a cart and open the servicing valve. (The
synthetic ball, had deteriorated resulting in valve will remain in the closed position
the failure. Subsequent testing of other and the leakage rate under this condition
valves at the location revealed nearly 50% should remain the same as in the test
were in the same dangerously potential above, assuming the leakage measured
situation. Periodic testing of the hydrant was the result of faulty piston seals).
valves would have prevented this situation Repeat the leakage test above. If the
15
leakage is significantly greater than that equipment less the pressure source but it
noted in the first test (assuming that the is not as complete and will not test the
leakage was well below the 500 cc/min. Servicing Valve. The Pilot Valve will remain
allowable), it is a good indication that the closed during all phases of this test.
pilot valve seals or valve stem are leaking
and in need of overhaul. If the leakage rate Close the Servicing Valve and conduct
is significantly lower, the first assumption the leakage test specified above.
that the majority of the leakage originally
Open the Servicing Valve and recheck
measured was through the piston seals
the leakage. If the leakage increases
was faulty and it could be an indication that
significantly, the pilot valve seals or valve
the seals of the servicing valve are faulty. If
stem assembly on Option X will be the
the leakage rate remains approximately the
contributor to the increased leakage. If the
same as in the first test, the pilot valve and
total leakage is less than 500 cc/minute,
servicing valve seals would appear to be
the valve can continue to be used. If
performing well and that the original
greater, replace it immediately.
assumption (leakage past the piston) was
correct. 7.2 DETAIL PARTS INSPECTION
Disconnect the test coupler and close It is recommended that the parts in the
the pilot valve (leave the 64230/ 64231 following table be replaced at each
Actuator disconnected on Option X) overhaul. Detail inspection of parts shall
before completing the test. be conducted in accordance with the
information in the following paragraphs.
Simple Test (will not test Servicing
Valve Seals) - This test can be conducted
on air operated units with the same
SAFETY NOTE:
Any and all quick disconnect fittings used to connect the air system to the hydrant valve must be configured
or altered to not tightly shut off the air pilot's air cavity. Without this feature, full hydrant system pressure
could build in the air pilot's air cavity as a result of the leaking air pilot. The hydrant would then be in an open
condition or would be a "hot" unit causing problems in connecting the coupler. This would defeat the safe
use of the hydrant as it was designed and would increase maintenance costs for the coupler.
Parts to be Replaced at Each Overhaul
Item Item
Number Description Number Description
1-32 O-ring 5-19 O-ring
2-10 Seal 5-26 O-ring
2-12 Seal 6-9 O-Ring
2-22 O-Ring 6-10 O-Ring
3-3 O-Ring (only if disassembled) 6-11 O-Ring
4-2 Gasket 6-15 Bal Seal
4-9 O-Ring 7-9 O-ring
4-22 O-Ring 7-15 Seal
4-28 Seal 8-15 Seal
5-1 O-ring 8-29 Pin
5-10, 7-40, Cable Assy (if cut during disassembly or
or 8-41 worn only )
16
7.2.1 Inspect all metal parts for dings, gouges, With a paint brush, apply one coat of
abrasions, etc. Use 320 grit paper to Henco-Phos 1326 Base (E/M
smooth and remove sharp edges. Corporation) in accordance with the
Replace any part with damage exceeding manufacturers instructions, and allow
15% of local wall thickness. Use alodine to air cure, approximately one hour.
1200 to touch up bared aluminum.
Utilizing a mixing dish and utensil, mix
7.2.2 If present, inspect Strainer (2-21) for the two part epoxy kit, Everlube 13-509
damage and presence of dirt. Clean (E/M Corporation), in accordance with
thoroughly to remove any potential instructions provided with the kit.
blockage.
Within a four hour period, liberally
7.2.3 Inspect the exterior sealing and interior apply the mixed Everlube 13-509
sealing surfaces on the outlet of the coating to the prepared surface, with a
Upper Half Assy (2-6), where it mates the paint brush in accordance with
hydrant coupler and where the Seal (2- instructions provided with the kit. Make
10) makes contact, for nicks, gouges or certain the entire prepared surface is
other distortions that may be a cause for coated. Allow to air cure until
leakage during operation. If the two-piece completely dry. Keep away from fuel or
upper housing is present and the sealing other solvents for at least 8 hours.
surface is damaged, replace Ring (3-4). 7.2.4 Check the underside of Ring (3-4) or the
Check the red coating, if present for chips same surface on Upper Housing (2-7) on
and missing portions. If the chips are older units. This is the 45 bevel that
apparent in the various sealing areas, it is contacts the lugs of the hydrant coupler.
necessary to strip and recoat the part. This surface should be smooth and
This can be accomplished by either of two continuous. If there are worn or flat spots
companies: on this surface, the part should be
E/M Corporation, 6940 Farmdale Ave., replaced.
North Hollywood, CA 91605, Telephone 7.2.5 Inspect the Lower Housing (4-11) for
(213) 875-0101. Their product is Everslik damage to the red coating as was done
1201 and is applied .001 to .005 thick. with the Upper Housing (2-7). Repair
Whitford Corporation, Box 2347, West such damage in accordance with the
Chester, PA 19380, Telephone, (215) instructions in paragraph 7.2.3 above.
296-3200, Fax (215) 647-4849. Their Check all sealing surfaces for nicks,
product is Xylan 1014 and is applied .001 gouges or other damage that might cause
to .005 thick. Whitford Corporation has leakage.
facilities or agents in various countries
throughout the world. Contact Carter or a Verify that the Orifice (4-29), located in
Carter distributor for more information one of the holes visible through the
about a local source. Servicing Valve (4-3) port in the Lower
Housing (4-11) has not been removed
If neither of these products are available, and not replaced during earlier overhauls.
an equal epoxy coating would be suitable This orifice controls the opening time of
provided the thickness is controlled to the the unit.
above limits. Limited repairs to the
surfaces that are not utilized for sealing 7.2.6 Inspect Poppet (4-4) for damage or to
purposes can be accomplished by using assure that the rubber portion is still
the process outlined in the following bonded in place. If there is a permanent
paragraphs. indentation in the sealing surface of the
rubber, discard and replace.
Degrease the entire area to be
repaired, plus approximately one (1) 7.2.7 Inspect Poppet (5-22, 6-3, 7-3 or 8-3) as
inch (25 mm) beyond, with a good in paragraph 7.2.6 above.
commercial degreasing solvent.
7.2.8 Inspect the sealing surface of the Housing
With an abrasive media, emery paper (6-1), (7-1) and (8-1), especially the inside
or steel wool, abrade the previously diameter in which the Piston (6-14), (7-14)
cleaned area, to the bare metal if and (8-14) slides. Polish out any
practical. irregularities that may have been caused
17
by incursion of dirt or corrosion using a 7.2.11 Inspect the lanyard Cable Assy (5-10), (7-
very fine emery cloth. Replace if the 37) or (8-41) for wear or fraying. Replace
irregularities can not be polished out as necessary.
completely.
7.2.12 Inspect Cable Retainer (7-33) or (8-34) on
7.2.9 Inspect the Latch Bracket (5-9) for wear Air/Lanyard Pilot Valve (1-F) or (1-U) for
or rounded edge where it contacts the wear, replace if worn.
Latch Spool (5-4). Replace if this corner is
rounded more than .04 (1 mm). 7.3 If after using the wear gauge in
accordance with paragraph 4.3 and the
7.2.10 Check the Latch Spool (5-4) corner that unit fails either the test using Side A or B
comes in contact with the Latch Bracket of the wear gauge, run older units replace
(5-9). If this corner is worn to more than the entire Upper Halve (2-7) with the two-
.04 (1 mm) replace the Latch Spool (5-4). piece Upper Half Assembly (3-1) and
newer units replace only the Ring (3-4)
and its O-ring (3-3).
8.0 REASSEMBLY
Reassemble in reverse order of 8.1.3 Place the Cover (2-23) onto the Upper
disassembly, noting the following: Housing (2-7) to protect the sealing
surfaces and turn the unit onto the
8.1 Upper Housing Assy (2-6) covered end. Install the Poppet Assy (2-8)
8.1.1 If 2-piece Upper Housing Assembly (2- into the Upper Housing Assy (2-7). Place
6A) is present and has been disassembled, the Spring (2-18) into the Poppet Assy (2-
place O-ring (3-3) in the groove in 8) and install the Poppet Retainer (2-19),
Housing (3-2) and install Ring (3-4) with holding it in position while inserting the
Screws (3-5) and Washers (3-6) using Retainer Ring (2-20) into the groove
Loctite (3-7). Torque the Screws (3-5) to within the Upper Housing (2-7). Once the
23-25 in-lbs. (24.5 - 26.5 cm-kg.) Note Retainer Ring (2-20) is seated, the
that screws should be thoroughly cleaned Poppet Retainer (2-19) can be released.
with acetone prior to using Loctite (4-7). 8.1.4 Turn the Upper Housing Assy (2-6) over
Install Seal, (2-12) into Poppet (2-11) and remove the Cover (2-23). Push the
such that the larger diameter bead of Poppet Assy (2-8) open and closed
rubber is positioned into the cavity in the several times to assure that there is no
Poppet (2-11) and the smaller diameter binding and that all parts are properly
bead of rubber will contact the retained.
equalization Poppet (2-13). Finish 8.2 Lower Housing Assy (4-1)
assembling the Poppet Assy (2-8), being
certain that the Retaining Ring (2-17) is 8.2.1 With the Lower Housing Assy (4-1)
fully seated within the groove in the placed such that the inlet flange is up (be
Poppet (2-11). The pressure equalization careful that the unit is placed on a smooth
Poppet (2-13) should protrude beyond the clean surface to prevent damage), insert
Poppet (2-11) and return to a seated O-Ring (4-24) into the groove in the
position when depressed by hand and Lower Housing (4-1). Hint: Grasp the O-
released. Ring (4-24) in both hands and stretch it
approximately 0.5 to 1.0 inch (12 - 25
8.1.2 Place the Seal (2-10) in the groove mm) before inserting into groove. Place
created by the assembly of the Poppet (2- Slipper Seal (4-25) such that the flanged
11) and Shroud (2-16). Using fingers only portion of the seal is facing upward (leg of
place the Seal (2-10) into the groove. seal into valve), carefully install it into the
Place one end of the Seal Ring (2-9) groove over the O-Ring (4-24). It will be
inside of the groove within the Seal (2-10) necessary to deform the Slipper Seal (4-
and wind it smoothly into the Seal (2-10) 25) into a slight "heart" shape to insert it
being sure not to have the Seal Ring (2-9) into the bore, however, do not exaggerate
cross over itself. the deformation and do not crease the
part. Smooth the installed Slipper Seal
18
(4-25) on its inside diameter with a thumb the Stem (4-6). Install O-Ring (4-9) onto
to assure there are no wrinkles. Place a Stem (4-6). Lightly lubricate O-Ring (4-9).
light coat of seal lubricant (specified Thread this assembly into Poppet
earlier in this document) onto the Slipper Retainer (4-8) until the hole in the Stem
Seal (4-25). (4-6) is well in the clear. Insert Pin (4-7)
into the hole and with the Stem (4-6) fully
8.2.2 Place O-Ring (4-22) into groove in Piston supported on a soft surface (block of
(4-18). Carefully insert Slipper Seal (4-23) wood or plastic), drive it into place until its
into the groove over the O-Ring (4-22). ends are approximately equally spaced
Smooth Slipper Seal (4-23) with finger to on each side of the Stem (4-6). Install
remove all possible wrinkles. Place a Gasket (4-2) onto the Poppet Retainer (4-
light coat of seal lubricant (specified 8) and lightly lubricate it. Set this
earlier in this document) onto the Slipper assembly aside for later reassembly into
Seal (4-23). unit.
8.2.3 Place Seal (4-21) onto the face of the 8.4 Air Operated Pilot Valve (1-E)
Piston (4-18) and smooth into place.
Place the Seal Retainer (4-20) onto the 8.4.1 Carefully install the Seal (6-15) onto the
Seal (4-21) and Piston (4-18) and hold in Piston (6-14) being certain that the open
place while installing Screws (4-19). portion of the "U" is facing away from the
Tighten Screws (4-19) evenly until the major portion of the piston (faces in the
heads contact the Seal Retainer (4-20). same direction as the Shaft (6-16)).
The Seal Retainer (4-20) is held in place Lightly lubricate it. If Shaft (6-16) was
by the heads of the Screws (4-19). removed it should be reinstalled.
Torque the Screws (4-19) to 14 inch-lbs
(16 cm-kg). 8.4.2 Drop Spacer (6-17) into its groove in the
Housing (6-1). (Note: if there is no groove
8.2.4 Place the flat Seal (4-28) in the piston to receive the Spacer (6-17), the unit is
cavity of the Lower Housing Assy (4-10). not a current production unit. Refer to
Insert the Washer (4-27) onto the Seal (4- paragraph 6.10 for information about the
28). Spring (4-26) is next placed to rest on identification of air operated pilot valves.).
Washer (4-27). Carefully guide the Piston Carefully install the Bal Seal (6-15) onto
Assy (4-18 to 3-23) into the Lower the Piston (6-14) being certain that the
Housing Assy (4-10) and push it with open portion of the "U" is facing away
even force until contact is made with from the major portion of the piston (faces
resistance of the seals. Continue even in the same direction as the Shaft (6-16)).
pressure until the Piston Assy (4-18 to 3- Lightly lubricate it. Place the assembled
23) is fully installed such that the Piston Piston (6-14) - Shaft (6-16) assembly into
Retainer (4-16) can be installed and held the Housing (6-1) and slowly push it into
in place with the Screws (4-15). Evenly place until resistance from the Bal Seal
tighten the Screws (4-15), then torque to (6-15) is encountered. Continue a
23 inch-lbs (26 cm-kg). downward even pressure on the parts
until the Piston (6-14) - Shaft (6-16)
8.2.5 Push Piston Assy (4-18 to 4-23) open and assembly is fully into the Housing (6-1). It
allow it to be closed by the Spring (4-26) may be wise to use an "orange stick"
several times to check for binding that (small round stick of hardwood with a
could be caused by pinched seals. flattened end) to assist in getting the Bal
8.2.6 If the Cage (shown as a part of the Pilot Seal (6-15) to evenly enter the Housing
Valve (1-D, 1-E, 1-F or 1-J)) (5-18 , 6-2, (6-1).
7-2 or 8-2) or the Valve Stem Assembly 8.4.3 Lightly lubricate O-Ring (6-9) and insert
(7-7) was removed from the Lower Half into counter bore in Housing (6-1) and
Assy (4-1), replace the O-Ring (5-1, 6-11, over Shaft (6-16). Push into place using
7-11, 8-11 or 9-8) and lightly lubricate it. O-Ring Retainer (6-8). (Note: O-Ring
Install it into the Lower Housing (4-1) and Retainer (6-8) is symmetrical and can be
tighten by hand with a wide blade inserted either end first).
screwdriver or in the case of the valve
stem assembly use special tool T221790. 8.4.4 Screw Adapter (6-5) onto Shaft (6-16)
until it bottoms. Place Spring (6-7) over
8.3 Servicing Valve (4-3) - Using snap ring Shaft (6-16) and onto O-Ring Retainer (6-
pliers, reassemble the Poppet (4-4) onto
19
8). Place Spring Retainer (6-6) into Spring Retainer (6-8) is symmetrical and can be
(6-7) and compress sufficiently to uncover inserted either end first).
the cross hole in the Adapter (6-5). Place
the Poppet (6-3) into the Adapter (6-5) 8.5.5 Screw Adapter (6-5) onto Shaft (6-16)
and align the holes in both the Adapter (6- until it bottoms. Place Spring (6-7) over
5) and Poppet (6-3). Push Pin (6-4) into Shaft (6-16) and onto O-Ring Retainer (6-
the hole and release Spring Retainer (6- 8). Place Spring Retainer (6-6) into Spring
6) to retain the Pin (6-4) and Poppet (6-3). (6-7) and compress sufficiently to uncover
the cross hole in the Adapter (6-5). Place
8.4.5 Note that the Cage (5-18 , 6-2, 7-2 or 8- the Poppet (6-3) into the Adapter (6-5)
2), although shown pictorially and and align the holes in both the Adapter (6-
furnished as part of the pilot valves, is 5) and Poppet (6-3). Push Pin (6-4) into
assembled into the Lower Half Assy (4-1). the hole and release Spring Retainer (6-
6) to retain the Pin (6-4) and Poppet (6-3)
8.4.6 When ready to install the Pilot Valve (1-E)
into the Lower Housing Assy (4-1), install 8.5.6 Note that the Cage (5-18 , 6-2, 7-2 or 8-
O-ring (6-10) onto Housing (6-1) and 2), although shown pictorially and
carefully insert the previously assembled furnished as part of the pilot valves, is
parts into the Cage (6-2), installed within assembled into the Lower Half Assy (4-1).
the Lower Housing Assy (4-1). Note:
When the Pilot Valve (1-E) is procured as 8.5.7 When ready to install the Pilot Valve (1-J)
a spare part, the Cage (6-2) is furnished into the Lower Housing Assy (4-1), install
as an integral part thereof. Insert Spring O-ring (6-10) onto Housing (6-1) and
(6-13) into Piston (6-14) and place Cover carefully insert the previously assembled
(6-12) onto Spring (6-13) compressing parts into the Cage (6-2), installed within
into place while inserting Screws (6-18) the Lower Housing Assy (4-1). Note:
and Washers (6-19). Torque to 120 inch- When the Pilot Valve (1-J) is procured as
lbs (138 cm-kg). a spare part, the Cage (6-2) will be
furnished as an integral part thereof.
8.5 Air Operated Pilot Valve - Defueling (1-J) Insert Wear Plate (6-20) and Spring (6-
13) into Piston (6-14) and place Cover (6-
8.5.1 Carefully install the Bal Seal (6-15) onto 12) with Screw (6-23) and Pin (6-24)
the Piston (6-14) being certain that the installed onto Spring (6-13) compressing
open portion of the "U" is facing away into place while inserting Screws (6-18)
from the major portion of the piston (faces and Washers (6-19). Torque to 120 inch-
in the same direction as the Shaft (6-16)). lbs (138 cm-kg). If Screw (6-23) and Pin
Lightly lubricate it. If Shaft (6-16) was (6-24) were removed for replacement,
removed it should be reinstalled reinstall prior to placing Cover (6-22) into
8.5.2 Place one Wave Washers (6-25) into the place.
piston bore of the Housing (6-1), then 8.6 Lanyard Operated Pilot Valve (1-D)
Washers (6-26) followed by the other
Wave Washers (6-25). 8.6.1 With Housing (5-2) in a suitable vise,
being careful not to damage part, place
8.5.3 Place the assembled Piston (6-14) - Latch Bracket (5-9) over corresponding
Shaft (6-16) assembly into the Housing holes in Housing (5-2) being certain that
(6-1) and slowly push it into place until the tang of the Latch Bracket (5-9) is
resistance from the Bal Seal (6-15) is correctly positioned to enter the Housing
encountered. Continue a downward, (5-2) slot. Tap Pins (5-8) into the Housing
even pressure on the parts until the (5-2), through the Latch Bracket, (5-9)
Piston (6-14) - Shaft (6-16) assembly is until Pins (5-8) are bottomed. Slide Cable
fully into the Housing (6-1). It may be Assy (5-10) through hole in Latch Bracket
wise to use an "orange stick" (small round (5-9), Latch Stop (5-11) and Spring (5-
stick of hardwood with a flattened end) to 12), then through the appropriate hole in
assist in getting the Bal Seal (6-15) to the Housing (5-2). Check, by pulling and
evenly enter the Housing (6-1). releasing Cable Assy (5-10), to confirm
8.5.4 Lightly lubricate O-Ring (6-9) and insert that there is free movement of the Latch
into counter bore in Housing (6-1) and Bracket against the Spring (5-12). Place
over Shaft (6-16). Push into place using Hose (5-13) into position and retain with
O-Ring Retainer (6-8). (Note: O-Ring Clamp (5-14). If a suitable tool is
20
available, the production Clamp (5-15) Adapter (5-21) and align the holes in both
can be used. A suggested tool is made the Adapter (5-21) and Poppet (5-22).
by National Telephone Supply Co., stock Push Pin (5-20) into the hole and release
number 51-X-850 or equivalent. Thread Spring Retainer (5-23) to retain the Pin (5-
the free end of the Cable Assembly (5-10) 20) and Poppet (5-22).
through the Clamp (5-15). Bend Cable
Assy (5-10) to form a suitable loop in the 8.6.8 Note that the Cage (5-18 , 6-2, 7-2 or 8-
free end. Thread the free end of the 2), although shown pictorially and
Cable Assy (5-10) back into the Clamp (5- furnished as part of the pilot valves, is
15) and crimp in place. If a suitable tool is assembled into the Lower Half Assy (4-1).
not available, use alternative Clamp (5- Install O-ring (5-19) onto Pilot Retainer (5-
15A) which utilizes two screws to retain 27) and carefully insert the above
the loop. assembled parts into the Cage (5-18) and
align the mounting holes with the
8.6.2 Place Spring (5-3) over Latch Spool (5-4) appropriate holes in the Lower Housing
and insert Latch Spool (5-4) into Housing Assy (4-1). Fasten in place with Screws
(5-2). Note that the Latch Bracket (5-9) (5-29) and Washers (5-28). Tighten
will have to be pulled out of the way by evenly and then torque to 120 inch-lbs
pulling upon the Cable Assy (5-10) while (138 cm-kg).
attempting to do this operation. Place
Latch Cover (5-5) over Latch Spool (5-4) 8.7 Air/Lanyard Pilot Valve (1-F)
such that the large open end protrudes 8.7.1 Reassemble in the reverse order of
over the Housing (5-2). If Ball (5-6A) is to disassembly noting the following:
be replaced, tap it onto the end of Handle
(5-6) that is farthest from the cross hole. 8.7.2 If the Cable Assembly (7-40) was cut,
Place Handle (5-6) over Latch Spool (5-4) replace with new part pulling it through
and align holes. With adequate support the Cable Retainer (7-33). Insert Ball
for the parts, tap Pin (5-7) to retain Retainer (7-32) into Cable Retainer (7-
assembly. 33). Install Spring (7-30) into Ball
Retainer (7-32). Assemble these parts
8.6.3 Pull Handle (5-6) and observe that the into Housing (7-34) and hold in
Latch Bracket (5-9) latches onto the Latch compressed position to insert Balls (7-31).
Spool (5-4). Pull the Cable Assy (5-10) to Install these parts into Connector (7-22).
release the Latch Spool (5-4). Screw on Lanyard Guide (7-29). Align
8.6.4 While applying pressure to the Cable holes in items (7-32) and (7-33) with slots in
Assy (5-10) to keep the Latch Bracket (5- (7-29). Press in Pin (7-21).
9) clear of the Latch Spool (5-4) and 8.7.3 Insert Poppet (7-24) into Shaft (7-28) and
Spring (5-3), Push Handle (5-6) inward to align hole for insertion of Pin (7-26). Hold in
force the Latch Spool (5-4) out of Housing place by installing Retainer (7-25). Place
(5-2) sufficiently to align Shaft (5-16) with Spring (7-27) over Retainer (7-25) and
Latch Spool (5-4) and install Pin (5-17). insert items into the open end of Connector
8.6.6 Place Pilot Retainer (5-27) over Shaft (5- (7-22). Align holes and insert second Pin
16) and move into groove in Housing (5- (7-21) to retain in place. Pull Cable (7-40)
2). Lightly lubricate O-Ring (5-26) and to open unit and not allow damage to
insert into counter bore in Pilot Retainer Poppet (7-24) during the next installation
(5-27) and over Shaft (5-16). Push into procedure. Screw in Seat (7-23) to a
place using O-Ring Retainer (5-25). bottomed position.
(Note: O-Ring Retainer (5-25) is 8.7.4 Slide Reset Ring (7-36) over cable with
symmetrical and can be inserted either lettering visible toward the cable. Install
end first). Retaining Ring (7-35) into the groove in
8.6.7 Screw Adapter (5-21) onto Shaft (5-16) Lanyard Guide (7-29) to retain. Slip Hose
until it bottoms. Place Spring (5-24) over (7-41) over end of Lanyard Guide and
Shaft (5-16) and onto O-Ring Retainer (5- retain in place with Clamp (7-39). If a
25). Place Spring Retainer (5-23) into suitable tool is available, the production
Spring (5-24) and compress sufficiently Clamp (7-38) can be used. A suggested
to uncover the cross hole in the Adapter tool is made by National Telephone
(5-21). Place the Poppet (5-22) into the Supply Co., stock number 51-X-850 or
equivalent. Thread the free end of the
21
Cable Assembly (7-40) through the Clamp 40A) which utilizes two screws to retain
(7-38). Bend Cable Assy (7-40) to form a the loop.
suitable loop in the free end. Thread the
8.8.5 Assemble the air piston section in
free end of the Cable Assy (7-40) back
accordance with paragraphs 8.4.
into the Clamp (7-38) and crimp in place.
If a suitable tool is not available, use 8.9 Option X Air/Lanyard Pilot Valve
alternative Clamp (7-38A) which utilizes Connector Assembly (1-X) - Valve Stem
two screws to retain the loop. Assembly (9-7) If this item was fully
disassembled, first replace Stem (9-11)
8.7.5 Assemble the air piston section in into the Cage (9-12). Then insert the
accordance with paragraphs 8.4. Spring (9-10) into the cavity in the stem
8.8 Air/lanyard Pilot Valve (1-U) and place the Spring Guide (9-9) keeping
the flat surface on the outside. Press the
8.8.1 Reassemble in the reverse order of spring guide into the cage to retain. Place
disassembly noting the following: the O-ring (9-8) onto the cage. Lubricate
the o-ring and insert the assembly into the
8.8.2 If the Cable Assembly (8-41) was cut, lower valve housing.
replace with new part pulling it through the
Cable Retainer (8-34). Insert Ball Retainer Lubricate and replace O-ring (9-3) into its
(8-33) into Cable Retainer (8-34). Install groove inside of the Connector (9-2).
Spring (8-31) into Ball Retainer (8-33). Lubricate and place O-ring (9-4) on the
Assemble these parts into Housing (8-35) shoulder of the connector. Install the
and hold in compressed position to insert connector onto the lower housing and
Balls (8-32). Install these parts into retain using Screws (9-5) and Washers
Connector (8-23). Screw on Lanyard (9-6). Insert a plastic rod into he
Guide (8-30). Align holes in items (8-33) connector and push the stem downward
and (8-34) with slots in (8-30). Press in to its stop. Release the rod and observe
Pin (8-22). that the stem retracts.
8.8.3 Insert Poppet (8-25) into Shaft (8-29) and 8.10 Final Assembly
align hole for insertion of Pin (8-27). Hold 8.10.1 With Lower Half Assy (4-1) set up such
in place by installing Retainer (8-26). that the piston (inlet) is against the work
Place Spring (8-28) over Retainer (8-26) bench, insert the Strainer (2-21) as
and insert items into the open end of applicable.
Connector (8-23). Align holes and insert
second Pin (8-22) to retain in place. Pull 8.10.2 Lightly lubricate and place O-Ring (2-22)
Cable (8-41) to open unit and not allow into the groove in the Lower Half Assy (4-
damage to Poppet (8-25) during the next 1).
installation procedure. Insert assembly 8.10.3 Be sure that the Stem (4-6) of the
into Housing (8-1) and secure with Servicing Valve (4-3) is fully screwed out,
Screws (8-20). install the Servicing Valve (4-3) into the
Lower Half Assy (4-1). Torque to 100-110
8.8.4 Slide Reset Ring (8-37) over cable with
ft lbs (13.83 to 15.21 m-kg). Do not over
lettering visible toward the cable. Install
tighten. (Some valves were wire locked at
Retaining Ring (8-36) into the groove in
the factory, but later versions substituted
Lanyard Guide (8-30) to retain. Slip Hose
this torque requirement for the wire
(8-42) over end of Lanyard Guide and
locking.)
retain in place with Clamp (8-40). If a
suitable tool is available, the production 8.10.4 Place the Upper Half Assy (2-6) onto the
Clamp (8-40) can be used. A suggested Lower Half Assy (4-1) such that the notch
tool is made by National Telephone in the mating flange is located opposite to
Supply Co., stock number 51-X-850 or the pilot valve boss. The one shorter
equivalent. Thread the free end of the Screw (2-5) is to be installed in the hole
Cable (8-41) through the Clamp (8-40). just to the left of the pilot valve boss.
Bend Cable (8-41) to form a suitable loop Install Screws (2-3 & 2-5) and Washers
in the free end. Thread the free end of (2-4) making sure that the Cover (2-23) is
the Cable (8-41) back into the Clamp (8- attached to one of the Screws (2-3). If
40) and crimp in place. If a suitable tool is product selection is used see paragraph
not available, use alternative Clamp (8- 8.8.5 before completing this section.
22
Tighten evenly and then torque to 120 8.10.6 Installation of the 60554 onto the mating
inch-lbs (138 cm-kg). flange should be done by loosely tightening
the mounting bolts evenly. The bolts
8.10.5 If Product Selection Assy (1-C) was
should then torqued in a normal cross
removed, replace it. Note that the
pattern in three successive steps. If the bolt
position of selection desired is achieved
pattern is numbered 1 through 8 in a
by placing one of the set of Bolts (1-3)
clockwise fashion, tighten in sequence
and stack of Washers (1-4 & 1-6) in the
1,5,3,7,2,6,4 and 8. The torque for the
hole numbered to the position. The other
three steps should be 40 ft-lbs (5.5 m-kg),
two selection sets are always located in
70 ft-lbs (9.7m-kg) and 93 ft-lbs (12.9 m-
the two un-numbered holes. It should be
kg).
noted also that the four Bolts (1-5) and
Standoffs, (1-2) used to mount the 8.10.7 Service Manual SM47076 covers the
product selector, replace the same installation of the 60554 into a 12 or 13-
number of Screws (2-3) and Washers (2- inch Avery Hardoll pit using option N of
4). the 60554.
9.0 TEST
9.1 Test conditions evidenced by fuel flow out of Poppet (2-
11). There shall be no leakage from unit.
Test media shall be JP-4, Jet A or odorless
kerosene, commercial solvent 140. 9.2.3 Servicing Valve Leakage - With the same
test setup, close Servicing Valve (4-3)
9.2 Functional Test and open Pilot Valve (1-D, 1-E, 1-F, 1-J or
The valve must be connected to a fluid 1-U) or on Option X attach either the
pressure source with capability of static 64230 or 64231 Actuator Assembly and
pressure of 300 psig, flow pressure open the Valve Connector Assembly (1-
(deadhead) of 120 psig and a flow rate of X). Apply 300 psig for one minute and
up to 1,100 USGPM. For the air operated observe for leakage. The Servicing Valve
units, a minimum of 120 psig air pressure (4-3) shall not open and there shall be no
must be available. evidence of leakage as evidenced by
leakage through the Poppet (2-11).
9.2.1 Leakage & Proof Pressure - Attach valve
to a static fuel pressure source of 300 9.2.4 Flow Tests - Install the valve in high flow
psig minimum. Open Pilot Valve (1-D , 1- test stand. Connect the outlet of the unit
E, 1-F, 1-J or 1-U) or on Option X attach to a Carter 61525 Coupler. Open Pilot
either the 64230 or 64231 Actuator Valve (1-D, 1-E, 1-F, 1-J or 1-U) or on
Assembly and open the Valve Connector Option X attach either the 64230 or
Assembly (1-X), open Servicing Valve (4- 64231 Actuator Assembly and open the
3) and fill valve manually opening the Valve Connector Assembly (1-X). With
Pressure Equalization Poppet (2-13) in 120 psig deadhead pressure establish a
the outlet Poppet (2-11) to allow trapped flow rate of 1100 USGPM.
air to escape. Blow the external wetness 9.2.4.1 Close the Pilot Valve (1-D, 1-E, 1-F, 1-J
off of the valve and pressurize the unit to or 1-U) or remove the Actuator Assembly
25 psig and 300 psig for a minimum of (Option X) and observe closing time
one minute at each pressure and observe and overshoot. Overshoot is defined as
for external leakage. There should be no the volume of fluid that passes through
leakage. the valve after the pilot valve has been
9.2.2 Seal Leakage - With the unit in the same closed. Closing time shall be 2 to 5
test setup, close pilot valve or remove the seconds and overshoot shall be less than
Actuator Assembly (Option X) and block 55 gallons at 1,100 USGPM.
the outlet Poppet open with a soft plastic 9.2.4.2 Opening Time - Using the same test setup,
rod (see paragraph 6.1 for hint). Apply 25 start with a closed valve and 120 psig dead-
and 300 psig for one minute at each head pressure, open Pilot Valve (1-D, 1-E,
pressure and observe for leakage as 1-F, 1-J or 1-U) or on Option X attach
either the 64230 or 64231 Actuator
23
Assembly and open the Valve Connector required for the valve to achieve at least
Assembly (1-X) and observe opening time. 90% of rated flow, 990 USGPM in this case.
Opening time is defined as the time The opening time shall be 5 to 10 seconds.
10.0 TROUBLE SHOOTING

10.1 External Leakage - Between Upper and Seal (6-15) should be evidenced by air
Lower Housing Assy (2-6 & 3-1). - Flange flowing out of the gap between the Cover
Screws (2-3 & 2-5) not tightened properly (6-12 , 6-2, 7-2 or 8-22) and the Housing
or O-Ring (2-22) pinched or cut. (6-1). On Option X check to see that the
64230/64231 is working properly see
10.2 Leakage past Servicing Valve (4-3). - SM64230/ SM64231.
Damaged Poppet (4-4).
10.7 On units with an Air Operated Defuel Pilot
10.3 Leakage past Equalization Valve Poppet Valve (1-J). - Valve will not open when air
(2-13). - Damaged Seal (2-12) or Poppet pressure is applied - Defuel Screw (6-23)
(2-13). is screwed in too far. Back out the Screw
10.4 Valve does not close when Pilot Valve (1- (6-23) until it is stopped by Pin (6-24).
D, 1-E, 1-F, 1-J or 1-U) or the Actuator 10.8 On units with an Air Operated Defuel Pilot
Assembly on Option X is closed. - If unit Valve (1-J). - Valve will not open to allow
closes when Servicing Valve is shut, defueling operation - Defuel Screw (6-23)
problem could be a damaged or leaking is not screwed in far enough. Be sure the
Pilot Valve Poppet (5-22 or 5-3), Stem (9- Screw (6-23) is bottomed out on the
11) or O-Ring (5-1, 6-11, 7-11, 8-11 9-8). Piston (6-14).
If Pilot Valve 1-E, 1-F, 1-J or 1-U is used,
check to see if Piston (6-14) is free to 10.9 On units with an Air Operated Defuel Pilot
travel open and closed. If Lanyard Pilot Valve (1-J). - Valve will not open to allow
1-D is used, check to see if Cable Assy defueling operation - Incorrect Piston Seal
(5-10) has been pulled to allow the pilot to Retainer (4-20) is installed. The correct
close. On Option X be sure to remove Seal Retainer (4-20) to have defueling cap-
air/fuel pressure from Actuator Assembly. ability is part number 207727. The height of
the Seal Retainer (4-20) should be
10.5 Valve does not close when Pilot Valve (1- approximately 0.540 (13.72 mm) to be
D, 1-E, 1-F, 1-J or 1-U) is closed, when correct. Replace Seal Retainer (4-20) with
air/fuel pressure is removed from Actuator correct part.
Assembly on Option X or when
Servicing Valve (4-3) is shut. - If flow rate, 10.10 On units with a Lanyard Operated Pilot
when attempting to close the valve, Valve (1-D). - If the valve won't open, check
changes very little, the problem could be to see that the Latch Spool (5-4) remains in
damaged Piston Slipper Seal (4-25) the locked up position. Pull and hold up the
and/or O-Ring (4-24) or jammed main Handle (5-6) for 30 seconds. If flow is
Piston (4-18). Check for movement established, the Latch Spool (5-4) is not
(manually) of Piston (4-18). If the flow locking in the open position. Problem could
rate changes to leakage when the valve is be wear either on the Latch Bracket (5-9) or
signaled to close, the problem could be Latch Spool (5-4).
the Piston Seal (4-21). Check also to be
sure that the piston on either the 64230 or 10.11 Fuel leakage into the air reference system
64231 Actuator Assembly on the hose is (on air operated pilot valve units only,
working properly. option E , F, J or U). - O-ring (6-9), (7-9)
or (8-9) needs replacing.
10.6 On units with an Air Operated Pilot Valve
(1-E, 1-F, 1-J or 1-U) or Option X - Valve 10.12 On Dual Pilot Units, Option F or U, if the
will not open when air pressure is applied valve does not open when deadman is
- Damaged Bal Seal (6-15), Piston (6-14) activated, manual pilot may need
is binding or damaged bore of Housing resetting to prevent the air pressure from
(6-1). Actuate with up to 80 psig air bleeding out of the unit.
pressure several times before checking
for leaking Bal Seal (6-15). Leaking Bal
24
11.0 ILLUSTRATED PARTS CATALOG

Tables 1.0 through 9.0 tabulate the parts comprising the various configurations and options of the
60554 Series of Hydrant Valves. The item numbers are keyed to the appropriate exploded view for
the option or sub-assembly as diagrammed.
TABLE 1
60554 Series Hydrant Valve and Options
Figure 1
Units/ Hydrant Spares/10

Fig. Item Part Number Description Assy Option Units/Yr.
1 C 44290 Product Selection Ring Assy 1 C -
1 207721 Ring 4 C -
2 207722 Standoff 4 C -
3 GF6-13 Bolt 3 C -
4 GF960-616L Washer 3 C -
5 GF5-35 Bolt 4 C -
6 GF960-616 Washer 27 C -
7 GF21083N6 Nut 3 C -
D 44248 Lanyard Pilot Valve 1 D -
42836 Lanyard Pilot Valve (Obsolete) - - -
E 44721 Pilot Valve, Air Operated 1 E -
44247 Pilot Valve (Obsolete) - E -
F 47091-1 Pilot Valve, Dual Air/lanyard for small pits 1 F -
X 47466 Valve Connector Assy 1 X
G 44364 6 X 4" IP Spool Assy 1 G -
10 207742 Adapter 1 G -
11 82154 Gasket 1 G -
12 82155 Bolt 8 G -
13 82156 Nut 8 G -
14 GF960-1016 Washer 16 G -
H 43587 Stone Guard Assy 1 H -
8 203331 Stone Guard 1 H -
9 RR-637-S Retaining Ring 1 H -
J 44570 Pilot Valve, Defueling 1 J -
K 44744 12" Pit Spool Assy 1 K -
11 82154 Gasket 1 K -
13 82156 Nut 8 K -
14 GF960-1016 Washer 8 K -
15 210341 Spool 1 K -
16 210384-36 Stud 8 K -
L 44745 13" Pit Spool Assy 1 L -
11 82154 Gasket 1 L -
13 82156 Nut 8 L -
14 GF960-1016 Washer 8 L -
16 210384-36 Stud 8 L -
17 210342 Spool 1 L -
25

1 M 44731 Quick Disconnect Assy 1 M -
18 B2K16-VB(S)DWC Male QD Fitting 1 M -
19 220013-01 Close Nipple 1 M -
20 47077 Adapter Kit, Option N installation 1 N -
21 47075 Adapter 1 N -
22 220345 Stud 8 N -
23 82156 Nut 8 N -
24 GF960-1016 Washer 8 N -
25 GF16997-171 Bolt 4 N -
26 5712-403-63 Washer 4 N -
27 MS29513-232 O-ring 2 N -
28 220343 Plate 1 N -
29 220342 Plate 1 N -
30 MS29513-237 O-ring (alternative to 31) 1 N -
31 220344 Gasket (alternative to 30) 1 N -
32 MS29513-246 O-ring 1 N 10
P 47199 6 X 4" Short (4) Spool Assy 1 P -
10 220965 Adapter 1 P -
11 82154 Gasket 1 P -
12 210384-22 Stud 8 P -
13 82156 Nut 8 P -
14 GF960-1016 Washer 16 P -
T 47326 Fusible Plug 1 T -
U 47361-1 Pilot Valve, Dual Air/lanyard large pit 1 U -
26
FIGURE 1
60554 SERIES HYDRANT VALVE OPTIONS
27
TABLE 2
Upper Housing Assy, Options A and B - Figure 2

2 3 GF16998-60 Screw 7 All -
4 GF960-516 Washer 8 All -
5 GF16996-32 Screw 1 All -
6A 47203-1 Upper Half Assy, 2-piece std. aluminum/st. st. 1 All but Q, R, S -
7 47159-1 Upper Housing Assy (See Table 3 for parts) 1 All but Q, R, S -
8 43795 Poppet Assy 1 All -
11 210284 Poppet - Steel 1 All -
200848-1 Poppet Obsolete, aluminum (Note 7) 1 All 1
12 221170 Seal 1 All 10
13 200011 Poppet, Pressure Equalization 1 All 2
14 200014 Spring 1 All -
15 200012 Retainer 1 All -
16 200849 Shroud 1 All -
17 RS-156-S Retaining Ring 1 All -
9 29472 Seal Ring 1 All 1
10 29486 Seal 1 All 10
18 28618 Spring 1 All -
19 200847 Retainer, Poppet 1 All -
6B 43214 Upper Half Assy, 1-piece ductile iron 1 Q -
12 221170 Seal 1 All 10
14 200014 Spring 1 All -
16 200849 Shroud 1 All -
18 28618 Spring 1 All -
6C 47203-2 Upper Half Assy, 2-piece ductile/st. steel. 1 R -
47159-2 Housing Assembly, ductile iron/st st 1 R -
(See Table 3 for parts)
10 29486 Seal 1 All 10
12 221170 Seal 1 All 10
14 200014 Spring 1 All -
16 200849 Shroud 1 All -
28

2 9 29472 Seal Ring 1 All 1
10 29486 Seal 1 All 10
18 28618 Spring 1 All -
6D 43214-4 Upper Half Assy, stainless 1 S -
7 29279-5 Upper Housing 1 S -
200848-1 Poppet Obsolete. Aluminum (Note 7) 1 All 1
12 221170 Seal 1 All 10
14 200014 Spring 1 All -
16 200849 Shroud 1 All -
10 29486 Seal 1 All 10
18 28618 Spring 1 All -
20 29288 Ring Retainer 1 All -
21 81557-10 Strainer, 10-mesh 1 A -
81557-20 Strainer, 20-mesh 1 B -
22 MS29513- O-Ring 1 All 10
165
23 41579 Cover Assy 1 All 3
1 28622 Cover 1 All 3
2 - Cable Assy (Note 3) 1 All -
24 5758-21C2 Washer, Retaining 1 All -
29
FIGURE 2 - UPPER HALF & OPTIONS A & B
30
TABLE 3.0
Standard and Option R Upper Half Assembly - Figure 3

3 1 47159-1 Housing Assembly, Aluminum/St. Steel 1 All but Q, R & S -
47159-2 Housing Assembly, Ductile Iron/St. Steel 1 R -
2 221289 Housing, aluminum 1 All but Q, R & S -
220844-2 Housing, Ductile Iron 1 R -
3 221118 O-ring 1 All but Q & S 10
4 220856 Ring, Coupler Connecting 1 All but Q & S 1
5 NAS1352N3-8 Screw 20 All but Q & S -
6 5710-159-16 Washer 20 All but Q & S -
7 603 Locktite, 10 ml. A/R All but Q & S 1
FIGURE 3 - 2-PIECE UPPER HALF
31
TABLE 4.0
Lower Half Assy - Figure 4

4 1 43219 Lower Half Assy 1 All but J -
44292 Lower Half Assy 1 J -
2 MS29512-12 Gasket 1 All 10
3 43272 Servicing Valve 1 All -
4 202597 Poppet 1 All 2
5 5008-62-H Retainer 1 All -
6 202631 Stem 1 All -
7 .156-1.000MDP Pin 1 All -
9 MS29513-010 O-Ring 1 All 10
10 42927 Lower Housing Assy 1 All -
11 202556 Lower Housing (Note 3) 1 All -
12 202593 Shaft (Note 3) 1 All -
13 5710-66-060 Washer 1 All -
14 GF51957-79 Screw 1 All -
15 NAS517-3-3 Screw 6 All -
16 202596 Retainer, Piston 1 All -
17 MS29513-249 O-Ring 1 All 10
18 202592 Piston 1 All Note 4
19 GF51958-62 Screw 6 All -
20 203032 Retainer, Piston Seal 1 All but J -
207727 Retainer, Piston Seal 1 J -
21 210127 Seal, Piston 1 All 10
22 MS29513-118 O-Ring 1 All 10
23 203030 Seal, Slipper 1 All 10
24 MS29513-245 O-Ring 1 All 10
25 202594 Seal, Slipper 1 All 10
26 202595 Spring 1 All -
27 203029 Washer 1 All -
28 203028 Seal 1 All 10
29 29224-7 Orifice 1 All -
32
FIGURE 4 - LOWER HALF ASSEMBLY (4-1)
33
TABLE 5.0
Lanyard Operated Pilot Valve - Figure 5

5 D 44248 Lanyard Pilot Valve 1 D Note 4
42836 Lanyard Pilot Valve (Obsolete) - - -
1 201201-014 O-Ring 1 All 10
2 202704 Housing 1 D -
3 202714 Spring 1 D -
4 202706 Spool, Latch 1 D -
5 202705 Cover, Latch 1 D 5
6 203533 Handle 1 D -
6A 47084 Ball 1 D -
7 GF16562-234 Pin 1 D -
8 GF51923-297 Pin 2 D -
9 202716 Bracket, Latch 1 D -
10 42954 Cable Assy 1 D -
11 202717 Stop, Release 1 D -
12 202715 Spring, Release 1 D -
13 81052 Hose 1 D 1
14 81094 Clamp, Hose 1 D -
15 82114 Sleeve 1 D -
15A 81095 Clamp, Cable 1 D -
16 207589 Shaft 1 D -
17 202743 Pin 1 D -
18 207718 Cage 1 All -
19 MS29513-114 O-Ring 1 All 10
20 GF9105-04 Pin 1 All 2
21 44252 Adapter 1 All -
22 207585 Poppet 1 All 5
24 202712 Spring 1 All -
25 202742 Retainer, O-ring 1 All 2
26 201201-008 O-Ring 1 All 10
27 202708 Retainer, Pilot Valve 1 D -
28 GF960-516 Washer 2 D -
29 GF35308-343 Bolt 2 D -
34
FIGURE 5 - LANYARD OPERATED PILOT VALVE
35
TABLE 6.0
Air Operated Pilot Valves, Options E & J - Figure 6

6 E 44721 Pilot Valve, Air Operated 1 E Note 4
1 47106 Housing (Newer Valves) 1 E -
208967 Housing (Obsolete) - E -
207600 Housing (Obsolete) - E -
2 207718 Cage 1 All -
3 207585 Poppet 1 All 5
4 GF9105-04 Pin 1 All 2
7 202712 Spring 1 All -
8 202742 Retainer, O-ring 1 All -
9 201201-008 O-Ring 1 All 10
10 MS29513-114 O-Ring 1 All 10
11 201201-014 O-Ring 1 All 10
12 207598 Cover 1 E -
13 207706 Spring 1 E, J -
14 44571 Piston 1 E, J -
44253 Piston (Obsolete) 1 E -
15 221290 Seal 1 E, J 10
16 207588 Shaft 1 E, J -
17 210176 Spacer 1 E -
18 GF16998-63 Screw 2 E, J -
19 GF960PD516 Washer 2 E, J -
J 44570 Pilot Valve, Defueling 1 J Note 4
1 47106 Housing (Newer Valves) 1 J -
208967 Housing (Obsolete) - E, J -
2 207718 Cage 1 All -
3 207585 Poppet 1 All 5
4 GF9105-04 Pin 1 All 2
7 202712 Spring 1 All -
9 201201-008 O-Ring 1 All 10
10 MS29513-114 O-Ring 1 All 10
11 201201-014 O-Ring 1 All 10
13 207706 Spring 1 E, J -
14 44571 Piston 1 E, J -
15 221290 Seal 1 E, J 10
16 207588 Shaft 1 E, J -
18 GF16998-63 Screw 2 E, J -
19 GF960PD516 Washer 2 E, J -
20 208958 Wear Plate 1 J -
21 47370 Screw Assembly 1 J -
22 221312 Cover 1 J -
208968 Cover (Obsolete) - J Note 6
23 221313 Screw 1 J
208959 Screw (Obsolete) - J Note 6
24 GF16562-213 Pin - J -
25 SSR0150-S17 Wave Washer 2 J -
26 5710-355-30 Washer 1 J -
27 5406-P-04 Plug 1 E, J -
36
FIGURE 6 - AIR OPERATED PILOT VALVES
37
Table 7.0
Air/Lanyard Operated Pilot Valve, Option F

7 1-FM 47091-1 Air/Lanyard Pilot w/option M (Note 5) 1 FM -
1-F 47091-2 Air/Lanyard Pilot (Note 5) 1 F -
1 47106 Housing 1 F, FM -
2 207718 Cage 1 All -
3 207585 Poppet 1 All 5
4 GF9105-04 Pin 1 All 2
7 202712 Spring 1 All -
9 201201-008 O-Ring 1 All 10
10 MS29513-114 O-Ring 1 All 10
11 201201-014 O-Ring 1 All 10
12 207598 Cover 1 F, FM -
13 207706 Spring 1 F, FM -
14 44571 Piston 1 F, FM -
15 221290 Seal 1 F, FM 10
16 207588 Shaft 1 F, FM -
17 210176 Spacer 1 F, FM -
18 GF16998-63 Screw 2 F, FM -
19 GF960-516 Washer 2 F, FM -
20 47093 Valve Assembly 1 F, FM -
21 .125-1.250LDP Pin 2 F, FM -
22 220410 Connector 1 F, FM -
23 220407 Seat 1 F, FM -
24 207585 Poppet 1 F, FM 5
25 207586 Retainer 1 F, FM -
26 GF9105-04 Pin 1 F, FM -
27 10460 Spring 1 F, FM -
28 220408 Shaft 1 F, FM -
29 220474 Lanyard Guide 1 F, FM -
30 C0210-026-125S Spring 1 F, FM -
31 220417 Ball 3 F, FM -
32 220412 Ball Retainer 1 F, FM -
33 220411 Cable Retainer 1 F, FM -
34 220409 Housing 1 F, FM -
35 220489 Retaining Ring 1 F, FM -
36 220475 Reset Ring 1 F, FM -
37 No Part Number Cable Assembly 1 F, FM -
38 82114 Sleeve 1 F, FM -
38A 81095 Clamp Assy (See 5-15A) 1 F, FM -
39 81094 Clamp 1 F, FM -
40 42954 Cable 1 F, FM 1
41 81052 Hose 1 F, FM 1
38
FIGURE 7 - AIR/LANYARD OPERATED PILOT VALVE, OPTION F
39
Table 8.0
Air/Lanyard Operated Pilot Valve, Option U

8 1-U 47361-1 Air/Lanyard Pilot Valve 1 U -
1-MU 47361-2 Air/Lanyard Pilot Valve w/Option M 1 MU -
1 47359 Housing 1 MU, U -
2 207718 Cage 1 All -
3 207585 Poppet 1 All 5
4 GF9105-04 Pin 1 All 2
7 202712 Spring 1 All -
9 201201-008 O-Ring 1 All 10
10 MS29513-114 O-Ring 1 All 10
11 201201-014 O-Ring 1 All 10
12 207598 Cover 1 MU, U -
13 207706 Spring 1 MU, U -
14 44571 Piston 1 MU, U -
15 221290 Seal 1 MU, U 10
16 207588 Shaft 1 MU, U -
17 210176 Spacer 1 MU, U -
18 GF16998-63 Screw 2 MU, U -
19 GF960-516 Washer 2 MU, U -
20 GF16997-45 Screw 3 MU, U -
21 47360 Valve Assembly 1 MU, U -
22 .125-1.000LDP Pin 1 MU, U -
23 221275 Connector 1 MU, U -
24 207585 Poppet 1 MU, U 5
25 207586 Retainer 1 MU, U -
26 GF9105-04 Pin 1 MU, U -
27 10460 Spring 1 MU, U -
28 220408 Shaft 1 MU, U -
29 .125-1.250LDP Pin 1 MU, U 10
30 220474 Lanyard Guide 1 MU, U -
31 C0210-026-125S Spring 1 MU, U -
32 220417 Ball 3 MU, U -
33 220412 Ball Retainer 1 MU, U -
34 220411 Cable Retainer 1 MU, U -
35 220409 Housing 1 MU, U -
36 220489 Retaining Ring 1 MU, U -
37 220475 Reset Ring 1 MU, U -
38 No Part Number Cable Assembly 1 MU, U -
39 82114 Sleeve 1 MU, U -
40A 81095 Clamp Assy (See 5-15A) 1 MU, U -
40 81094 Clamp 1 MU, U -
41 42954 Cable Assy 1 MU, U 1
42 81052 Hose 1 MU, U 1
40
FIGURE 8 - AIR/LANYARD OPERATED PILOT VALVE, OPTION U
41
Table 9
Connector Valve Assembly Figure 9

9 1-X 47576 Air/Lanyard Pilot Valve Connector 1 X -
Assembly
1 47574 Connector Assembly 1 X -
2 221791 Connector 1 X -
3 M25998/1-012 O-ring 1 X 10
4 MS29513-114 O-ring 1 X 10
5 GF35308-330 Screw 2 X -
6 GF960-516 Washer 2 X -
7 47573 Valve Stem Assembly 1 X -
8 201201-014 O-ring 1 X 10
9 221792 Spring Guide 1 X -
10 K-30 Spring 1 X -
11 221789 Stem 1 X -
12 221790 Cage 1 X -
RETROFIT INFORMATION
Existing 60554 Air Operated Hydrant Valves can be retrofitted as follows:
1. Order one 47576 Valve Connector Assembly (for air/fuel operation) kit (shown to the right) for each
hydrant valve,
2. Order special tool T221790 (only one per airport is needed).
3. Remove and discard the existing pilot valve and cage from the hydrant valve.
4. Using the special tool screw the cage into the hydrant valve body.
5. Once the 48573 is seated and tightened install the 47574 Connector Assembly using the two screws
provided.
6. Retrofit the hydrant servicers by ordering one each 64230 or 64231 Actuator Assembly as
appropriate to your operation for each servicer. Replace the existing disconnect on the hose to the
hydrant valve with the 64230/64231 as appropriate. It is recommended that at least one spare
64230 or 64231 Actuator Assembly be ordered for each airport.
42
FIGURE 9
AIR/FUEL PILOT VALVE CONNECTOR ASSEMBLY OPTION X
43
Table 10
KITS for Maintenance
The following kits are available for maintaining the units as noted:
KIT NUMBER DESCRIPTION - CONTENTS COMMENTS
KD60554-1 This kit is for use in repairing/overhauling any 60554 Hydrant Replaces KD60554 Kit.
Valve less the Pilot Valve and contains 2-10, 2-12, 2-22, 3-3,
4-2, 4-4, 4-9, 4-17, 4-21, 4-22, 4-23, 4-24, 4-25 & 4-28.
KD60554-2 This kit is for use in repairing a complete 60554D Hydrant Valve
including the Lanyard Operated Pilot Valve and contains 2-10,
2-12, 2-22, 3-3, 4-2, 4-4, 4-9, 4-17, 4-21, 4-22, 4-23, 4-24, 4-25,
4-28, 5-1, 5-5, 5-19, 5-22 & 5-26 .
KD60554-3 This kit is for use in repairing a complete 60554E or 60554J

Hydrant Valve including either the Air Operated Pilot Valves
with or without the defueling option and contains 2-10, 2-12, 2-
22, 43-3, -2, 4-4, 4-9, 4-17, 4-21, 4-22, 4-23, 4-24, 4-25, 4-28,
6-3, 6-9, 6-10, 6-11, 6-13 & 6-15.
KD60554-4 This kit is for use in repairing older Hydrant Valves with For 60554D Valves with
obsolete 42836 Pilot Valve and contains 2-10, 2-12, 2-22, 3-3, obsolete 42836 Pilot Valves.
4-2, 4-4, 4-9, 4-17, 4-21, 4-22, 4-23, 4-24, 4-25, 4-28, 5-1, 5-5,
5-19, 5-26 & Seal 202711.
KD60554-5 This kit is for use in repairing older Hydrant Valves with For 60554E and J Valves with
obsolete 42846 Pilot Valve and contains 2-10, 2-12, 2-22, 3-3, obsolete 42846 Pilot Valves.
4-2, 4-4, 4-9, 4-17, 4-21, 4-22, 4-23, 4-24, 4-25, 4-28, 6-9, 6-10,
6-11, Seal 600-015-10, MS29513-218, & Seal 202711.
KD60554-6 This kit is for use in repairing or converting 60554E or J Valves Valves using this kit may have
for use at temperatures down to -65 F and contains 2-22, 3-3, limited operation life at normal
4-2, 4-4, 4-9, 4-17, 4-21, 4-22, 4-23, 4-24, 4-25, 4-28, 6-10 , operating temperatures and the
6-11, & O-ring MS29513-014, Poppet 220424, Seal 220425, conversion may be only useful
Seal 220426, & Seal 220427. during the winter months.
KD60554-7 This kit is for use in repairing a complete 60554F or 60554U

Valves complete with Dual Air/Lanyard Pilot Valve and contains
2-10, 2-12, 2-22, 3-3, 4-2, 4-4, 4-9, 4-17, 4-21, 4-22, 4-23, 4-24,
4-25, 4-28, 6-3, 6-9, 6-10, 6-11, 6-13 & 6-15
KD64055-8 This kit is for use in converting any one piece upper housing
(except option S) to a two-piece aluminum/stainless steel
upper. It contains 3-3, 3-4, 3-5 and 3-6.
KD60554-9 This kit is used to upgrade hydrant valves with serial numbers This kit provides the steel
8454 to 11160 to meet the requirements of the 3rd Edition of poppet and the two piece upper
API 1584 items 6A, housing required for older valves
to meet the requirements.
KD60554-10 This kit is used to upgrade later hydrant valves with the This kit is used to upgrade the
aluminum poppet assembly but with the appropriate upper half poppet assembly only to the
(aluminum housing with the replaceable stainless steel steel version to meet the
interface ring). Serial numbers 11161 and subsequent. requirements.
2KD42836 Kit to Upgrade the old style Lanyard Operated Pilot Valve,
42836, to the newer production style, 44248, allowing the use
of current production hardware - items 5-1, 5-5, 5-16, 5-19,
5-20, 5-21, 5-22, 5-23 & 5-26.
44
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.
3. These items are not sold as separate parts, only the next assembly is available.
4. It is recommended that at least one each be on hand for each 50 or less hydrant valves in the
system.
5. Air/Lanyard Pilots can be purchased without the Cage (7-2) or (8-2) and O-ring (7-11) or (8-
11) if it is desired to replace the unit as a complete pilot valve. The Cage (7-2) or (8-2) and O-
ring (7-11) or (8-11) can then be left installed inside the hydrant valve and need not be
replaced. The part numbers for this replacement pilot valve would be 47091-3 for Option F
pilot valve without the M Option or 47051-4 with the M Option. For Option U pilot valve without
M Option it would be 47362-3 or with Option M it would be 47362-4.
6. The obsolete items 22-24 in Table 6 are no longer available as spare parts. If any one of the
parts is ordered it will automatically be replaced with 47370 Screw Assembly.
7. The obsolete item 2-11 is no longer available as a spare part. If it is ordered it will be replaced
by KD60554-10 to upgrade the poppet to the latest steel version.
45

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Carter Ground Fueling Division

Revised September 2006

1.0 INTRODUCTION ..........................................................................................................3

MAINTENANCE, OVERHAUL & TEST INSTRUCTIONS

2.0 EQUIPMENT DESCRIPTION

Lower Housing Assembly - Various options are available to modify the

3.0 TABLE OF OPTIONS & ORDERING INFORMATION

4.0 SAFETY INSTRUCTIONS/PREVENTATIVE MAINTENANCE

4.3 OUTLET SAFETY INSPECTION - The

Second, attempt to pass side B across the

Figure A reflects a lanyard

Figure B reflects the same

Servicing Valve Closed Pilot Valve Closed

small bladed screwdriver into the hole in

Piston Retainer (4-16). The later versions

Parts to be Replaced at Each Overhaul

10.0 TROUBLE SHOOTING

11.0 ILLUSTRATED PARTS CATALOG

Units/ Hydrant Spares/10

Units/ Hydrant Spares/10

60554 SERIES HYDRANT VALVE OPTIONS

Units/ Hydrant Spares/10

Units/ Hydrant Spares/10

FIGURE 2 - UPPER HALF & OPTIONS A & B

Units/ Hydrant Spares/10

FIGURE 3 - 2-PIECE UPPER HALF

Units/ Hydrant Spares/10

FIGURE 4 - LOWER HALF ASSEMBLY (4-1)

Units/ Hydrant Spares/10

FIGURE 5 - LANYARD OPERATED PILOT VALVE

Units/ Hydrant Spares/10

FIGURE 6 - AIR OPERATED PILOT VALVES

Units/ Hydrant Spares/10

FIGURE 7 - AIR/LANYARD OPERATED PILOT VALVE, OPTION F

Units/ Hydrant Spares/10

FIGURE 8 - AIR/LANYARD OPERATED PILOT VALVE, OPTION U

Units/ Hydrant Spares/10

Existing 60554 Air Operated Hydrant Valves can be retrofitted as follows:

AIR/FUEL PILOT VALVE CONNECTOR ASSEMBLY OPTION X

KIT NUMBER DESCRIPTION - CONTENTS COMMENTS

KD60554-3 This kit is for use in repairing a complete 60554E or 60554J

KD60554-7 This kit is for use in repairing a complete 60554F or 60554U

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