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SM60427

1. Attaches Nose Seal to Nozzle Body Prevents rotation of nozzle collar Keeps Lock Pin extended Provides proper alignment between nozzle and aircraft receptacle Provides seal between body and valve seat assembly Provides seal between body and valve seat assembly Holds Crank Handle in place FAILURE MODE Fails closed Torn or broken Missing or broken Cracked or loose Missing 1 or 2 Stuck retracted 1 or 2 Missing all 3 Stuck retracted All 3 Stuck extended Installed backwards or upside down Missing or broken 1 or 2 Missing or broken All 3 Missing 1 or 2 Missing all 3 Missing Torn or broken Missing Torn or broken Missing or loose SM60427 RESULT OF FAIL Cannot refuel Fuel Spray Nose seal does not stay completely in place minor fuel leak Poppet valve may be blocked from closing Fuel spray None None Loss of nozzle collar interlock Can flow fuel without nozzle attached to aircraft Same Cannot attach nozzle to aircraft Cannot assemble nozzle None Loss of collar interlock depending on orientation of aircraft receptacle Can flow fuel without nozzle attached to aircraft None Difficulty attaching nozzle to aircraft Fuel Spray Fuel leak Fuel Spray Fuel leak Handle separates 22 HAZARD CATEGORY V 1 4 3 3 4 V 1 V 1 4 4 V 1 V 1 V 1 4
2. Cap Screw 2 Handle 10 Handle 15 Bumper Ring Collar bearing Collar Poppet Cotter Pin Poppet FUNCTION Protects nozzle lugs and valve when not in use Holds handle in place Holds handle in place Provides bearing surface for handle bolt Rotates collar to attach or detach nozzle Rotates collar to attach or detach nozzle Rotates collar to attach or detach nozzle Provides gripping surface for handle Provides bearing surface for handle grip bolt Holds handle grip in place Rotates collar to attach or detach nozzle Rotates collar to attach or detach nozzle Protects lug ring on collar Retain nozzle collar to nozzle body Secures nozzle to aircraft receptacle Prevents poppet from turning and loosening from shaft Shuts off fuel flow FAILURE MODE Torn or missing Missing or loose Missing or loose Missing broken or installed backwards Missing bent or broken Missing bent or broken Missing bent or broken Missing or torn Missing broken or installed backwards Missing or loose Missing bent or broken Missing bent or broken Missing or torn Broken or galled Missing Cracked or Broken Damaged Ball Grooves Cracked worn or bent lugs Broken or missing lug s Missing or broken Fails open Cracked or broken RESULT OF FAIL None Handle separates Handle separates None Cannot attach nozz
3. The following special tools are recommended for proper repair and or overhaul of the nozzle 64000 poppet adjustment gauge e 6958CG or 6958CH adapter or equivalent The above items are available from your Eaton Carter brand distributor 6 0 DISASSEMBLY 6 1 Remove nozzle from end of hose at quick NOTE Do not engage nozzle onto an adapter disconnect Refer to the appropriate service This will create a load on Bearing 8 Manual opariding Upon type or swivel 65 Remove nozzle Collar 9 from Body 39 by disconnect utilized e i aligning the groove in the Collar 9 with square boss on the side of the Body 39 SM40679 Standard 60427 nozzle disconnect 6 6 Turn Crank Handle 21 or 21A to open Poppet SM42275 High flow disconnect JIS thread only 11 or 11A SM427MISC Miscellaneous male half adapters 6 7 Remove Cotter Pin 10 and unscrew the SAS nae with GORIBIBIO Poppet 11 or 11A from the Shaft Assembly 38 Older nozzles will have a Poppet 11 that SM60129 1 Hose end control valve HECV is green in color Teflon coated while the Y SM60672 1 Old style dry break disconnect option Poppet 11 is black Newer nozzles will have a golden colored anodized aluminum SMBEISE Nawstylady breake disconnect Poppet 11 as standard The nozzles with this SM64015 Ball valve poppet also have a Shaft 38 which has two holes drilled in the threaded end The golden i colored Poppet 11 can only be utilized if there If Drag Rin
4. eE GF16997 78L Cap screw 1 All but S amp V 6F 220000 Handle 1 All but G S amp V No number 43003 2 Handle assy set 15 Note 10 1 G 2 2 MS21042 4 Nut self locking 2 All 3 Left intentionally blank 4 GF4 13A Bolt hex head 2 All 5 GF960 416 Washer 4 All 6A 203241 2 Handle 15 2 G ec 207808 Grip 2 All but S amp V 5 eD GF960 516 Washer 2 All but S amp V eE GF16997 78L Cap screw 2 All but S amp V eG 220001 Handle 2 G No number 43003 3 Handle assy set stirrup note 10 1 S 2 2 MS21042 4 Nut self locking 2 All 3 Left intentionally blank 4 GF4 13A Bolt hex head 2 All 5 GF960 416 Washer 4 All 6B 200479 Handle stirrup 2 S 7 23622 Bumper 1 All 10 8 23620 Bearing 1 All 3 9 28085 Collar 1 All 2 10 GF24665 302 Cotter Pin 1 All 10 11 26866 Poppet std green obsolete 1 All but Y amp Z 1 11 210593 Poppet std gold current Note 11 1 All but Y 1 11A 29649 Poppet Russian black 1 Y 1 11 SM60427 May 2013 Units Spares 10 Item Part Number Description Assy Nozzle Option units Yr 12 209029 Nose seal 1 All but Z 10 12A 222486 Nose seal Arctic 1 Z 10 13 24636 Ring snap 1 All but Z 14 24779 Plate 1 All 15 207789 Lock pin 3 All 3 16 20909 Spring 3 All 3 17 24780 Index pin 3 All 3 18 201201 145 O ring 1 All 10 18A M25988 1 145 O ring 1 Z 10 19 2
5. V 1 V 1 4 3 4 3 V 1 HAZARD PROBABILITY REAL HAZARD INDEX 12 12 12 12 12 12 12 2013 CORRECTIVE ACTION Same as above Replace Nose Seal Replace Snap Ring Shutoff fuel at Source Aircraft poppet valve will prevent backflow Pressure test prior to use Replace Lock Pin s Same as above Procedural error also needed for fuel spill Valve link has overcenter feature to prevent fuel pressure from opening valve Same as above Replace Lock Pin Install Correctly Replace Lock Spring s Same as above Replace Index Pin Same as above Pressure test prior to use Same as above Pressure test prior to use Same as above Use another handle NR 20 21 28 29 30 31 32 33 34 35 36 37 38 39 40 COMPONENT Handle Lock Washer Crank Handle Washer Lock Wire Busing Spacer O Ring Wave Washer Washer Gasket Crank Cotter Pin Crank Crank Shaft Body Access Port Plug 2 FUNCTION Provides bearing surface for Crank Handle Screw 1 Applies force to open poppet valve 2 Prevents collar from rotating Provides bearing surface for Crank Handle Locks bushing to housing Provides clearance between nozzle body and Crank Handle Retains o ring Provides seal between crank shaft and Body Provides crankshaft tension Provides bearing su
6. ball valve Use instead of 6 Adds male adapter half 43046 to mate option H from part 1 above standard female quick disconnect 43108 amp old style dry break QD 60672 1 3DE Adds ball valve with glass inspection port and Adds male adapter half to mate 61154 dry break drag ring when the regulator is used any F option 44185 J Adds handle spanner for 8 Adds male adapter half to mate 61154 dry break operation inspection quick disconnect when used without regulator any F option 44700 R Adds hex key for defuel operation 9 Adds male adapter half to mate with high flow female QD includes 100 mesh screen Only available as complete QD with 3 JIS inlet thread 42275 3 Specify together with U from part 4 Adds options to number 3 of part 3 above only Safety clip P N 210641 for the 61154 dry break QD is considered FOD Foreign Object Damage and is not included on military nozzle assemblies however it can be added as a no cost option SM60427 May 2013 PART 4 One of the following letters must be included as Part 4 as indicated above to specify the inlet thread and size Option Option Letter Description Letter Description H Inlet thread 2 N Inlet thread 2 BSPP K Inlet thread 2 BSPP P Inlet thread 2 NPT L Inlet thread 3 NPT U Inlet thread 3 JIS only available with option 9 from part 3 only Inlet thread 3 BSPP Z Inlet thread 3 JIS only
7. boss on the Body 39 as shown in figure 2 Ball 45B is first dropped into the threaded hole and then Bolt 45C is fastened against the Ball 45B and Cable 45A to retain it in place Option E Vacuum Breaker 46 is installed in lieu of one of the Plugs 40 Do not use more than 17 wraps of Teflon tape when installing it Tighten only to seal the hexagon head should not touch the Body 39 since this is an American NPT type tapered thread Option T Gauge 47 is shown in Figure 2 This option includes in addition to the actual gauge a guard to protect the gauge and two screws for mounting the guard Screws 47A are longer than the normal screws furnished with the disconnects and regulators to account for the extra thickness of the Guard 47B The Gauge is mounted in the NPT port provided in the Body 39 Again use no more than 11 2 wraps of Teflon tape for seal Safety Clip 50 as shown in Figure 3 is available only with options 4 5 7 amp 8 Part 3 The Clip 50 is installed in the groove adjacent to the red sleeve on the dry break disconnect to prevent the inadvertent movement of the sleeve until the Clip 50 is moved to the groove closest to the hose end of the unit SM60427 May 2013 9 0 TEST The nozzle should be tested as a complete unit fully closed to fully open position a minimum of including th
8. is more than one regulator available Refer to SM42275 for parts listing Refer to 5 40679 for parts listing means that there is additional information required to complete the part number Refer to SM61 154 for parts listing means that there is additional information required to complete the part number Refer to SM60672 1 for parts listing means that there is additional information required to complete the part number This item has been superseded by 61154 and is no longer available as an option to the 60427 nozzle Handle Assy 43003 1 2 and 3 include all of the parts shown indented under their respective listings Example 43003 1 includes 2 each of items 2 6 item 6 includes 6C 6D 6E amp 6F 210593 Poppet 11 can be used only with Shaft 38 which has two holes present in the threaded end of the part Rework instructions are shown in Figure 5 Option Y nose seal and poppet to fit older Russian aircraft can utilize either the obsolete 29650 or the current production 209029 interchangeably Refer to SM64001 for parts listing means that there is additional information required to compete the part number Refer to SM64015 for parts listing means that there is additional information required to compete the part number 13 SM60427 May 2013 TABLE 2 0 Torque Specifications 60427 Fig Item Part Number Description Torque in Ib 1 30 20914 Bushing 120 150 in Ib 138 173 kg cm SM60427 May 2013 1
9. life of an item Will occur frequently Occasional Likely to occur sometimes in the life of an item Will occur several times Remote So unlikely it can be assumed that this hazard Unlikely to occur but possible will not be experienced Extremely Improbable Probability of occurrence cannot be So unlikely it can be assumed that this distinguished from zero hazard will not be experienced Impossible Physically impossible to occur Physically impossible B Hazard Severity Hazard severity categories are defined to provide a qualitative measure of the worst potential consequences resulting from personnel error environmental conditions design inadequacies procedural deficiencies or system subsystem or component failure malfunction Severity Category Descriptive word Results Il IV Catastrophic May cause death or system loss Critical May cause severe injury or system damage Marginal May cause minor injury minor occupational illness or minor system damage Negligible Will not result in injury occupational illness or system damage Real Hazard Index RHI Matrix RHI Hazard Severity X Probability Level SEVERITY 4 I 3 IM 2 1 A 6 24 18 12 6 B 5 20 15 10 5 PROBABILITY C 4 16 12 8 4 D 3 12 9 6 3 E 2 8 6 4 2 F 1 4 3 2 1 General guidelines for required action RHI 1 8 No action required 9 12 Special precautions required investigate redesign 13 24 Hazardous redesign necessary or pr
10. nicked Broken scratched or nicked Broken missing loose or stripped Broken Broken Broken or nicked Broken Broken missing loose or stripped Broken Broken or loose Broken Broken Broken Broken Broken Broken Broken Broken Broken RESULT OF FAIL Unrestrained piston assembly Uncontrolled pressure regulation failed to lock out Uncontrolled pressure regulation Leakage coming out of vent port Uncontrolled pressure regulation failed to lock out Leakage coming out of vent port Uncontrolled pressure regulation failed to lock out Leakage coming out of vent port Permanent lock out Failed to lock out Failed to lock out Uncontrolled pressure regulation failed to lock out Leakage coming out of vent port No effect Uncontrolled pressure regulation failed to lock out Leakage coming out of vent port Failed to lock out Failed to hold locked out pressure Failed to lock out Failed to hold locked out pressure Failed to lock out Failed to lock out Uncontrolled pressure regulation failed to lock out Leakage coming out of vent port Uncontrolled pressure regulation failed to lock out Leakage coming out of vent port Uncontrolled pressure regulation failed to lock out Leakage coming out of vent port External leakage External leakage 25 HAZARD SEVERITY IIl 2 IIl 2 HAZARD PROBABILITY
11. perform a major overhaul for the 604276H 6K 6P amp 6Z consists of items 1 6C 7 8 9 10 12 18 28 32 33 35 amp 36 above plus 201201 231 amp 201201 151 O rings KD60427 9 Parts necessary for a seal change for the 604276H 6K 6P options old part number 60427J Identical to the 3 kit except the O ring material is fluorosilicone Consists of items 10 12 18 M25988 1 145 28 32 M25988 1 014 33 35 M25988 1 910 amp 36 above plus M25988 1 231 M25988 1 151 M25988 1 233 amp M25988 1 039 O rings 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 an AN part otherwise it is interchangeable with an MS part of the same number 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 82267 2 replaces 82267 1 for oversize hole applications Refer to SM427MISC for parts listing Refer to 5 60129 1 for parts listing indicates that there is additional information required to complete the part number since there
12. will be a small quantity of trapped fuel in the nozzle Check to see if there is a Cotter Pin 10 installed through the slotted poppet and the hole in the shaft The pin must be installed in the hole that is completely within the slotted area of the poppet and the hole that allows for proper poppet nose seal adjustment Older nozzles will have a Cotter Pin 10 that has an overall length of approximately 1 05 inches 26 7 mm The pin on the newer nozzles will be approximately 1 35 inches 34 3 mm long If the new longer Cotter Pin 10 part number GF24665 302 is available it is recommended that the existing pin be removed and the new Cotter Pin 10 installed in accordance with Figure 6 If the new pin is not available it is recommended that the Cotter Pin 10 be checked to assure that the longer leg is bent into a partially circular loop such that the loop is as close to the shaft as possible The shorter leg should be bent to an angle as close to 90 as possible Grasp the Poppet 11 or 11A with one hand and holding the nozzle with the other attempt to un screw the 11 or 11A from the Shaft 38 The poppet will move a slight amount taking up the slack between the slot in the 11 or 11A the hole in the Shaft 38 and the Cotter Pin 10 If all is correct close the nozzle and remove the adapter flange Put the nozzle back in service SM60427 May 2013 5 0 SPECIAL TOOLS i 61657 2 adapter wear gauge
13. 1 14A ong C IT 10 6B FIGURE 1 SM60427 May 2013 DETAIL A DETAIL B WO 46 FIGURE 2 SM60427 May 2013 Older nozzles utilize O Ring retained Screen where applicable Refer to SM60427 for detail FIGURE 3 SM60427 May 2013 69 REF 17 53 ___ 226 5 740 MM EXISTING HOLE DRILL 109 2 769 MM DIA THRU RADIAL LOCATION WITH RESPECT TO EXISTING HOLE NOT CRITICAL FIGURE 4 SHAFT REWORK INSTRUCTIONS 18 SM60427 May 2013 210593 POPPET ASSY POPPET amp SHROUD SHROUD REF GF24665 302 COTTER PIN FIGURE 6 POPPET SHAFT RETENTION 19 SM60427 May 2013 FAILURE MODES AND EFFECTS ANALYSIS Nozzle Notes that apply to this analysis A Hazard category hazard probability and real hazard index RHI are defined herein B Visual inspection means examining the nozzle for obvious cracks damage and broken lugs prior to initial pressurization C Pressure test prior to use means pressurizing the nozzle and attached hose to operating fuel pressure then removing pressure prior to aircraft arrival D Shut off fuel at source will be the first action for any leak To further improve operating safety this procedure should be used for all refueling operations In addition fuel flow should be turned on at the source not at the nozzle E Item numbers referred to in this section are those used in Figure 5 RISK ASSESSMENT A
14. 20004 Screw 1 All but S 1 20 GF35338 43 Lockwasher 1 All but S 21 28086 Handle crank 1 All but S 2 21A 44725 Handle crank assembly 1 S 2 21B 156 1 000MDP Pin 1 S 5 21C 220128 Handle 1 S 22 27 Left intentionally blank 28 21706 Washer 1 All 2 29 GF20995C32 Wire lock A R All 1 Roll 30 20914 Bushing 1 All 1 31 20910 Spacer 1 All 2 32 201201 014 O ring 1 All 10 33 22291 Washer wave 2 All 8 34 22290 Washer 2 All 6 35 MS29512 10 Gasket 1 All 10 36 82267 1 Cotter Note 3 1 All 2 37 20916 Crank 1 All 38 40006 Shaft 1 All 39 41427 Body 1 All 40 210388 Plug 2 All 1 only option E 2 41 41600 Adapter male flight refueling note 4 1 R E 42 60129 1 Hose end regulator note 5 1 F4 F5 43 42275 3 High flow disconnect JIS thread note 6 1 9U 44 40679 Quick disconnect Note 7 1 6H K N P amp Z 45 41768 Grounding cable kit 1 D 45 4646 Grounding cable 1 D 45B GF19060 1008 Ball 1 D 45C GF74A11 Bolt 1 D 46 41599 Vacuum breaker 1 E 47 41770 Gauge kit 1 T E 47A GF16997 60 Screw 2 T 47B 29028 Guard 1 T 47C 80673 Gauge 1 T 48 61154 Dry break QD new style note 8 1 7 amp 8H K N P 49 60672 1 DB QD old style note 9 1 50 210641 Safety Clip 1 STD w 4 5 7 88 51 64001 Low friction swivel quick disconnect note 13 1 4 amp 5H K N P 52 64015 Ball valve note 14 1 3H K L N P 53 220460 Drag ring 1 H 10 54 41767 60 Screen assy 60 mesh 1 6 R 41676 100 Screen assy 100 mesh 54A 4
15. 4373 60 Screen assy 60 mesh 1 4 5 7 8 44373 100 Screen assy 100 mesh 55 43046 Adapter male std disconnect 1 6 56 44185 Adapter short male 1 7 4 57 44700 Adapter long male 1 8 5 12 Notes 10 11 12 13 14 SM60427 May 2013 Kits KD60427 1 Parts necessary for a seal change for the 604276H 6K 6P amp 6Z options old part number 604274 Consists of items 10 12 18 28 32 33 35 amp 36 above plus 201201 231 amp 201201 151 O rings Replaces old kit 80676 KD60427 2 Parts to make the seal change as in KD60427 1 above plus parts to replace the seals in a hose end regulator options F3 F4 or F5 Contains KD60427 1 plus KD60129 1 KD60427 3 Parts to include seal changes to the basic nozzle KD60427 1 plus the o ring to repair the old style dry break disconnect 60672 1 Contains KD60427 1 plus 201201 233 KD60427 4 KD60427 2 plus KD60427 3 to repair a 60427 nozzle with hose end regulator plus 60672 1 dry break disconnect KD60427 5 Parts to repair the 60427 nozzle KD60427 1 plus parts to repair the 61154 new style dry break disconnect Contains KD60427 1 plus KD61 154 1 KD60427 6 Parts to repair the 60427 nozzle plus parts to repair the hose end regulator and 61154 dry break disconnect Contains KD60427 1 KD60129 1 and KD61154 1 KD60427 7 Parts to provide replacements to allow use of common current production poppet with 60427 nozzle Contains items 10 11 210593 amp 38 KD60427 8 Parts to
16. 50 F 37 to views or in the separate manuals referenced as 66 C The basic nozzle would be procured as accessory to this manual 3 0 TABLE OF OPTIONS amp ORDERING INFORMATION The basic Model 60427 is available with a variety of options to customize it to meet specific requirements as listed in the table below The various options when compatible PART 1 Model Number configuration PART 4 Letter describing the inlet thread size amp type PART 3 Number describing the male adapter required to mate the desired inlet PART 2 Options B Z describing various changes to the basic configuration may be combined and listed following the model number 60427 to achieve a complete unit The model number of a complete nozzle consists of four basic parts as illustrated below PART 2 SM60427 May 2013 The following options may be added as Part 2 of the part number as indicated above to order a unit to meet your requirements Option Letter Description Option Letter Description B 60 mesh strainer Adds drag ring 100 mesh strainer R Flight refueling male half D Grounding cable S Stirrup handle package E Vacuum breaker T Pressure gauge obsolete Deletes handles nozzle shipped less 35 psi regulator V handles F4 45 psi regulator Y Russian nose seal obsolete Fb 55 psi regulator Z Arctic weather nozzle G Adds 15 handles Options amp C only available
17. E T N Powering Business Worldwide Eaton Aerospace Group Fluid amp Electrical Distribution Division Carter Ground Fueling Equipment Maintenance amp Repair Manual Underwing Refueling Nozzle Model 60427 SM60427 May 2013 Supersedes release February 2013 Applicable additional manuals SM40679 SM60129 1 SM60672 1 SM61154 SM427MIS SM64001 SM64015 TABLE OF CONTENTS Page 1 0 Introduction to HH Die nte eie 3 2 0 Equipment Description 4 4 460 nennen 3 3 0 Table of Options amp Ordering Information sess 3 4 0 Safety Instrctions ote e e t egeo rd itera e p dag 5 5 0 Special Tools sii tette ete edat etat 8 6 0 Disassembly uie hne Heat Eg 8 FOJ InspectiOEi coe i eene e ett 9 8 0 9 9 0 osten eee etta ede Petites 11 10 0 Illustrated Parts Catalog 2 404440 0 11 Figure ds sd tet eee inl eaten 15 Figure 25 9 16 Figure SE ace tecti et eai Ri red dtum bee 17 gis 18 Figure 19 11 0 Failure Modes And Effects Analysis 221 20 12 0 Failure Modes And Effects Analysis Hose End Control Valve 24 SM60427 Maintenance Overhaul amp Test Instruc
18. REAL HAZARD INDEX 6 CORRECTIVE ACTION Inspect prior to installation into system Inspect prior to installation into system Inspect prior to installation into system NR 21 25 26 27 28 29 29 29 31 COMPONENT Breather Assembly Screw Assembly O Ring Ball Bearing O Ring Housing Assembly Outer Wear Ring Inner Wear Ring Continuity clip FUNCTION To prevent atmospheric contaminants from entering inner piston cavity To provide containment for balls item 27 and to prevent external leakage To prevent external leakage To secure mechanical connection to mating part To prevent external leakage House all components Provide harden bearing surface to protect aluminum housing To provide electrical continuity bonding to mating component FAILURE MODE Missing or loose Broken or loose Broken Broken Broken Cracked Broken Broken SM60427 RESULT OF FAIL Contamination of inner piston cavity External leakage External leakage Damage ball race External leakage External leakage Total failure Exposing aluminum housing ball bearing race to wear No ESD protection 26 HAZARD SEVERITY HAZARD PROBABILITY REAL HAZARD INDEX RHI May 2013 CORRECTIVE ACTION Inspect prior to use Inspect prior to use Inspect prior to installation into system Inspect prior to use Ae
19. aircraft or needs repair or the aircraft adapter is in need of repair NOZZLES INSPECTIONS MONTHLY BASIS The following inspections of the nozzle are recommended to be conducted on a monthly basis as a minimum A Inspect the connection end and verify that the three Index Pins 17 are intact and in place Verify that the three Collar Lock Pins 15 are intact and in place and extended and engaging all three cutouts in the Collar 9 and physically preventing Collar 9 rotation Check the Bearing Plate 14 containing the pins for possible cracks 4 3 3 SM60427 B Hold the nozzle with the outlet or connecting end facing such that it can be observed Apply pressure on the Collar 9 in the direction to connect the nozzle to an aircraft counter clockwise to take up the slack and inspect the relative location of the three Lock Pins 15 with respect to the cutouts in the Collar 9 The two Lock Pins 15 that are engaged in the normally narrower cutouts should be resting against the edge of their respective cutouts If there is a space between the third Lock Pin 15 and the edge of the normally larger cutout the collar is still in functional condition If all three Lock Pins 15 are resting against the edge of their respective cutouts there is no space the Collar 9 may no longer be in a functional condition and should be replaced if it fails the next step of the inspection 4 3 4 C With the nozzle being held i
20. available with option 6 from part 3 only Not available with ball valve option 3 from part 3 above Examples 60427BDF36H Nozzle with 60 mesh screen grounding cable 35 psi regulator and 2 1 2 NPT 40679 1 QD 60427CF5F57K Nozzle with 100 mesh screen two 55 psi regulators and 2 1 2 BSPP 61154JK dry break QD 60427C8K Nozzle with 100 mesh screen and 2 1 2 BSPP 61154DK dry break The following table should be used to determine the service manual to be used in the maintenance repair or replacement of parts designated by option letters to the basic 60427 nozzle Option Option Letter Part Number Service Manual Letter Part Number Service Manual B 41767 60 5 40679 4 44185 5 64001 C 41767 100 5 40679 4H 64001 5 64001 D 41768 SM60427 5 44700 SM64001 E 41599 SM60427 5H K P 64001H K P SM64001 F 60129 1 SM60129 1 6 43046 SM40679 G 43003 2 SM60427 6H K P amp Z 40679 SM40679 R 41600 5 427 5 7 44185 5 61154 5 43003 3 5 60427 7H 61154H 5 61154 os 41770 SM60427 8 44700 SM61154 b fal 29649 amp 29650 SM60427 8H K P 61154H K P 5 61154 2 47101 5 60427 90 42275 3 5 42275 3H K L N P 64015 SM64015 Three different regulators are available Refer to the following pages regarding part numbering for more details Option T pressure gauge and option Y Russian nose seal available only as long as inventory of the parts is available Nozzles with th
21. ccidental rotation of the Collar of the disengaged nozzle One of the three cutouts in Collar 9 is normally elongated more than the other two With the Collar 9 locked in the disengaged position the flat portion of a ramp integral to the Collar 9 is positioned over a flat on the Crank Handle 21 or 21A in a manner that prevents opening the Poppet 11 or 114 4 3 1 When connecting to an aircraft the three Index Pins 17 mate with three slots in a serviceable MS24484 Adapter Flange to index the nozzle to the flange so the Collar 9 mates with the flange lugs during engagement and prevents disengagement of the Collar 9 from the flange without releasing the three spring loaded Collar Lock Pins 15 to the Collar 9 lock positions CRANK HANDLE COLLAR INTERLOCK AND OVER CENTER LINKAGE Examination of the center portion of the Crank Handle 21 or 21A on a disengaged nozzle discloses the fact that a flat edge of the Crank Handle 21 or 21 is beneath the flat portion of a ramp that is integral to the Collar 9 With the Collar 9 locked by the Collar Lock Pins 15 the Collar 9 ramp prevents rotation of the Crank Handle 21 or 21 to the poppet open position When the Collar 9 is fully engaged to serviceable MS24484 Adapter the Collar ramp clears the Crank Handle 21 or 21A and permits rotation to the open position With the Crank Handle 21 or 21 fully open the round portion of the Cran
22. ces Wash all parts with cleaning solvent Federal Specification P D 680 or equivalent and dry thoroughly with a clean lint free cloth or 8 3 compressed air 84 WARNING Use cleaning solvent in a well ventilated area Avoid breathing of fumes and excessive solvent contact with skin Keep away from open flame 8 5 NOTE A light coat of petroleum jelly can be applied to all o rings springs and screws for ease of installation 8 6 the boss on the side of the nozzle Body 39 The Cotter Pin 36 may be installed with the use of needle nose pliers taking care to bend both ends over to secure it Install the Gasket 35 onto the Bushing 30 Install and tighten the Bushing 30 to 120 150 in Ib 138 173 kg cm to be held in place with Lockwire 29 Insert the two Wave Washers 33 and two Washers 34 alternately refer to Figure 1 the O ring 32 the o ring Spacer 81 and the Washer 28 Install the three lock pin Springs 16 three Lock Pins 15 three Index Pins 17 and O ring 18 Install the Plate 14 onto the Seal 12 or 12 Install Snap Ring 13 The installation of the 8 7 8 8 8 9 8 10 SM60427 Ring 13 is optional Nozzles coming from the factory will continue to contain this part If the Snap Ring 13 is not used it is possible to replace the Nose Seal 12 or 12A without removing the Collar 9 One will have to be able to open the nozzle without it being install
23. dly distorted and enlarged it should be inspected more closely and accurately Adapter Wear Gauge 61657 2 should be utilized to check the width and thickness of the lugs if they appear to be worn Wear of the thickness dimension of the lug will promote premature nose seal leakage Wear of the width May 2013 of the lug combines with slot wear in defeating the nozzle interlock B Visually check the three slots for excessive wear Excessive wear can permit disengagement of a nozzle without release of the three Collar Lock Pins 15 and may permit accidental poppet opening on the disconnected nozzle The use of Wear Gauge 61657 2 will provide a no go check for the slots C If any of the above conditions are observed and or the gauge proves the adapter to be defective the refueling operation should be continued only with extreme caution The nozzle upon disconnection should be checked in accordance with paragraph 4 3 1 A POPPET SHAFT RETENTION INSPECTION This inspection procedure must be conducted following the removal and reinstallation of the Poppet 11 or 11 from the Shaft 38 e Using Eaton s Carter brand part number 5204451 three lug adapter flange or any standard flange that is a separate loose part and not a part of some other adapter housing open the nozzle being careful to drain all trapped fluid into a suitable container Even if the ball valve or a dry break disconnect is utilized there
24. e appropriate quick disconnect dry five times There shall be no evidence of binding break and or regulator or excessive force required for valve actuation 9 1 Test conditions 9 4 Leakage Test Test media shall be Stoddard Solvent Federal 9 4 1 With the nozzle outlet in the normal open Specification P D 680 JP 4 per MIL J 5624D position and the test adapter outlet closed at 75 15 F Jet A or equivalent pressurize the inlet to five 5 psig and hold for one minute minimum There shall be no evidence of external leakage from the nozzle 9 3 Functional Test 9 4 2 Repeat the leakage test at 60 psig and 120 9 3 1 The nozzle shall be inserted and locked into a psig test adapter and the nozzle valve actuated by use of the Crank Handle 21 or 21 from the 29 docu e dE the nozzie and repeal 10 0 ILLUSTRATED PARTS CATALOG Table 1 0 tabulates the parts and sub exploded views of the regulator diagrammed in assemblies comprising the 60427 nozzle The Figures 1 2 and 3 item numbers of the table are keyed to the TABLE 1 0 Units Spares 10 Item Part Number Description Assy Nozzle Option units Yr 1 207799 Cover assembly 1 All 10 No number 43003 1 Handle assy set 10 Note 10 1 All but G S amp V 2 2 MS21042 4 Nut self locking 2 All 3 Left intentionally blank 4 GF4 13A Bolt hex head 2 All 5 GF960 416 Washer 4 All 6 203241 1 Handle 10 2 All but G S amp V 6C 207808 Grip 1 All but S amp V 5 6D GF960 516 Washer 1 All but S amp V
25. e nozzle by removing 39 to pass through the slot in the Collar 9 On Pin 21B later models the regular stick type Handles 6 or 6 11 R i i i emove the Lockwire 29 from the Bushing xin are an assembly with replaceable Grips 6C 30 Note method of lockwiring so that it may be eld in place with Screw 6E and Washer 6D d plisated onteassembl Remove Grip 6C from Handle 6F or G only if it is p necessary to replace it 6 12 Using needle nose pliers remove the Cotter Pin 6 3 Using a sharp knife cut the Bumper 7 to 36 remove it from the Collar 9 6 13 Remove the Bushing 30 o ring Spacer 31 6 4 Push at one end of the collar Bearing 8 to Wee Me Ge Wave cause the other end to protrude from groove Using pliers pull the collar bearing out of 6 14 The Crank 37 and Shaft Assembly 38 may groove On parts where the Bearing 8 is difficult to remove it is suggested that the outlet end of the nozzle be soaked in light motor oil over night to assist in removing it now be removed from flange end of Body 39 It is not recommended that the Shaft Assembly 38 be disassembled further If replacement is required replace as an assembly SM60427 May 2013 6 15 The plugs 40 or Vacuum Breaker 46 do not necessary have to be removed unless replacement is 7 0 INSPECTION 7 1 It is recommended that all O rings 18 and 32 Check Bearing 8 to be sure it is not worn Gasket 35 and Nose Seal 12
26. e old style dry break Model 60672 1 were sold under options TT through YY to the basic nozzle Model 60672 1 is out of production and has been superseded by Model 61154 dry break quick disconnect The male and female halves of the 61154 are not interchangeable with either the 60672 1 series male and female halves The entire dry break disconnect must be replaced The male half adapter 43046 is still available as a spare part However if the female half is required as a replacement for a 60672 1 a complete 61154 appropriate options specified will have to be ordered SAFETY INSTRUCTIONS There are several safety interlock features consequential risk of fire personal injury or designed into the Model 60427 nozzle that must death and property damage Refer to Table 1 0 be functioning to prevent an accident that would Section 10 0 to identify individual parts during result in a spill of flammable liquids with the the following discussion COLLAR ASSY LOCK AND INDEX PINS Collar 9 and the Nose Seal 12 or 12A The M i three spring loaded Collar Lock Pins 15 Examination of the connection end of a engage three cutouts arched shaped windows disengaged nozzle not connected to an adapter in the flange of the Collar 9 when the Collar is discloses the three Collar Lock Pins 15 and in the fully disengaged position These Collar three Index Pins 17 installed between the x ae i 4 2 4 3 SM60427 Lock Pins 15 prevent a
27. ed to an adapter A standard three lug adapter flange with the three lugs removed will serve nicely for this application It should be noted that when the 8 12 nozzle is opened in this manner the Nose Seal 12 or 12A may follow the Poppet 11 or 11 out of the nozzle If this is not acceptable either use the Ring 13 or simply apply pressure by hand to the Nose Seal 12 or 12A as the nozzle is opened to keep it in place Install the Seal 12 or 12A Plate 14 and Ring 13 if used into the nozzle Body 39 8 13 being careful not to displace O ring 18 Install this assembly of parts so the three Index Pins 17 and three Lock Pins 15 pass through the six holes in the Plate 14 Install the Collar 9 on the Body 39 matching the groove in the Collar 9 with the square boss on the body Secure by inserting Bearing 8 into the Collar 9 bearing groove The Crank Handle 21 or 21C may now be installed and held in place with the use of the Lockwasher 20 and the Screw 19 or Pin 21B Use the Crank Handle 21 or 21A and turn the Crank 37 position to install the Poppet 11 or 11 Before inserting the Cotter Pin 10 adjust the Poppet 11 or 11A to 020 040 inch 508 1 016 mm above the top of the face of the 8 16 collar If the golden colored Poppet 11 is utilized the Shaft 38 must have two holes present in the threaded portion If there is only one hole the green Poppet 11
28. g option H is present it is are two holes present Rework instructions to sandwiched between the male and female add the second hole to allow the use of the halves of the disconnect Set aside for later lower cost Poppet 11 are included as Figure 5 Inspection On the golden colored Poppet 11 do not try to 6 2 Remove the cover assembly 1 from nozzle remove the permanently assembled shroud on Before proceeding further it is recommended the curved side of the unit that the inspections detailed in paragraph 4 3 2 6 8 The Nose Seal 12 or 12A may be removed be conducted to get an overall picture of the Remove Snap Ring 13 from Seal 12 or condition of the nozzle Take special note of the 12A Lift off Plate 14 wear check of the Collar 9 detailed in 4 3 2 B If all three cutouts of the Collar 9 are touching 6 9 The three Lock Pins 15 three lock pin Springs the Lock Pins 15 the Collar 9 should be 16 three Index Pins 17 and O ring 18 may replaced during overhaul now be removed If the Handles 6 6A or 6B are to be replaced 6 10 After removal of the Screw 19 and the remove hardware items 2 4 amp 5 If they do not Lockwasher 20 the Crank Handle 21 and need replacing remove only the that Handle 6 Washer 28 may be removed Newer models 6A or 6B that is farthest away from the Crank utilize a single piece Crank Handle 21A it may Handle 21 to allow the indexing lug on the Body be disassembled from th
29. ine on the link along the i clevis end of the rod Pull the link directly away e Measure the through bore of the Bushing 30 from the rod and scribe another line Measure It shall not exceed 0 499 inches 12 675 mm tne distance between the scribed lines with a Attach the Crank Handle 21 or 21A to the vernier caliper to determine the looseness square boss on the Crank 37 using the e Measure the diameter of the boss on the appropriate hardware If the Crank Handle 21 Crank 37 that mates with Shaft Assembly 38 or 21A is not held tightly to the Crank 37 the It shall not exceed 0 313 handle should be replaced Measure the small hole through the boss of e If Drag Ring 53 option is present the Crank 37 through which Cotter 36 is inspect to determine if the part is still capable of inserted If the hole is 0 115 or larger it is protecting the HECV body If the outside recommended that Cotter 36 part number be diameter of the Drag Ring 53 is less than 4 60 revised to the oversized one 82267 2 be used inch 117 mm replace it to prolong the life of the Crank 37 8 0 REASSEMBLY Reassemble in reverse order of disassembly 8 2 The Crank 37 and Shaft Assembly 38 may noting the following now be inserted in the nozzle body 39 with the 8 1 Make certain all components are clean and free Shalt nation OIM Coran CHO extending rem from oil grease or any other corrosion resistant compound on all interior or exterior surfa
30. ion A Inspect the connection end and verify that the Index Pins 17 are intact in place and not excessively worn or damaged Verify that all three Collar Lock Pins 15 are intact undamaged and are extended to engage all three cutouts in the Collar 9 and physically prevent Collar 9 rotation This inspection can be accomplished without interruption of the normal operating procedure and without adding appreciably to the operation time by training the operator to automatically observe the connection end of the nozzle upon disconnection from the aircraft If the Collar Lock Pins 15 are not extended and engaged in all three cutouts in the Collar 9 the operator should squeeze the Crank Handle 21 or 21 and Handle 6 6A or 6B together while observing the connecting end of the nozzle This should cause the Collar Lock Pins 15 to spring into the cutouts in the Collar 9 If not then the nozzle should be taken out of service If the Collar Lock Pins 15 do not spring into their correct position it could mean that the aircraft adapter is defective and should be inspected see paragraph 4 3 3 and reported as possibly being defective B Upon engagement to an aircraft and opening the nozzle but before operating the deadman control it is recommended that the operator attempt to remove the nozzle from the aircraft This should not be possible If it can be removed either the nozzle was never fully engaged onto the
31. k Handle 21 or 21A prevents rotation of the Collar 9 in the disengage direction until the Crank Handle 21 or 21A has been fully closed These interlocks are designed to prevent accidental opening of the poppet while disengaged or accidentally disengaging a nozzle with the poppet open The poppet operating internal linkage design is such that the linkage is over center at each extreme of travel for Crank Handle 21 or 21 to fully open against internal mechanical stop or to fully closed against internal mechanical stop 4 3 2 Thus internal pressure against a closed poppet when the linkage is against the closed mechanical stop provides a force only in the closed direction In a similar manner with the Crank Handle 21 or 21A in the fully open mechanical stop position the 50 Ib force applied by the MS24484 Adapter Poppet Spring provides a force to maintain the open direction SAFETY INSPECTIONS May 2013 The frequencies recommended for the following inspections are our recommendations based on nozzles that have been in daily service for at least a year The frequency that is required will depend upon the degree of maintenance extended to the equipment and to the age of the equipment It is not possible for Eaton to recommend other than the safest possible frequencies NOZZLE INSPECTIONS AT EACH REFUELING OPERATION The following inspections of the nozzle are recommended at each refueling operat
32. le Cannot attach nozzle Cannot attach nozzle None None Handle separates Cannot attach nozzle Cannot attach nozzle Possible ring damage no hazard Difficulty in connecting to aircraft Unit unusable Difficulty in connecting to aircraft Difficulty in connecting to aircraft Improper seal resulting in fuel leak Nozzle released from aircraft receptacle resulting in fuel spill spray 1 Valve may loosen and prevent complete fuel shutoff 2 FOD from pin prevents valve closure Fuel may leak Fuel flow can t be shutoff Fuel flow can t be shutoff 21 HAZARD CATEGORY HAZARD PROBABILITY 3 D REAL HAZARD INDEX RHI 3 12 12 12 12 12 CORRECTIVE ACTION Visual Inspection Use another Nut Use another Bolt Use another Washer Use another Assembly Same as above Same as above Replace Grip Use another Washer Use another Screw Use another Handle Same as above Visual Inspection Replace Visual Inspection Visual Inspection Same as above Same as above Same as above Replace Cotter Pin Same as above 1 Pressure test prior to use 2 Shut off fuel at source Same as above NR COMPONENT Nose Seal Snap Ring Nose Seal Plate Lock Pin 3 Lock Pin Spring 3 Index Pin 3 Body O Ring Body O Ring Handle Screw FUNCTION Seals poppet valve in body Holds Plate onto Nose Seal
33. must be used or the Shaft 38 must be reworked in accordance with Figure 5 With the Crank 37 rotated to the full closed position the top of the Poppet 11 or 11 should be approximately in the middle of the concave surface area of the nose seal 8 17 Use of the Poppet Adjustment Gauge 64000 will facilitate the achievement of the correct adjustment Install the Cotter Pin 10 in the Shaft Assembly 88 as shown in Figure 6 Be sure that both 8 11 8 14 8 15 10 May 2013 legs of the Cotter 10 are bent Turn Crank Handle 21 or 21A to closed position Make sure the Cotter Pin 10 ends are securely bent over to retain in place Install Bumper 7 It is best to warm the Bumper 7 in water at 160 180 F to soften before pressing onto Collar 9 Install Handle 6 6A or 6B being sure to first insert it through the loop which is a part of the Cover 1 to retain it Use the appropriate hardware items 2 4 amp 5 to secure the Handle 6 6A or 6B in place If on later models the Grip 6C is to be replaced attach it to Handle 6F or 6G with Screw 6E and Washer 6D Cover 1 can now be placed over outlet of unit Accessories such as quick disconnects dry break quick disconnects and hose end regulators can be installed with the hardware and o ring provided with each Option D grounding cable can be installed by inserting the end of the Cable Assembly 45A into the hole in the
34. n the position described above attempt to open the nozzle with the Crank Handle 21 or 21A The nozzle should be prevented from opening by the interference between the Collar 9 and the Crank Handle 21 or 21 If the nozzle can be opened it should be removed from service and repaired D Inspect the Crank Handle 21 or 21 and the adjacent ramp surface of the Collar 9 and verify that neither part is damaged or has missing pieces that permit the Crank Handle 21 or 21 to be rotated to the open position with the nozzle disengaged or that will allow the Collar 9 to rotate to the disengaged position when the Crank Handle 21 or 21 is open Broken or missing parts can result in dangerous fuel spills while refueling aircraft E Verify that the Crank Handle 21 or 21A is in the fully closed position against internal mechanical stop This is necessary to assure that the linkage is over center so internal pressure can not force the poppet open during the Collar 9 engagement AIRCRAFT ADAPTER INSPECTIONS The following inspections of the aircraft adapter are recommended to be carried out at each refueling operation to assure that one is connecting to a safe adapter A Visually check for bent broken missing or excessively worn lugs or slots Worn slots are easily detected A normal slot will have a slight machine broken edge chamfer of 030 inch 0 762 mm If the edge is worn such that the corner is ba
35. ocedural control if redesign is impractical 24 SM60427 May 2013 12 3 FAILURE MODES AND EFFECTS ANALYSIS FMEA Refer to Figure 1 for component numbers mentioned in column one NR 20 COMPONENT Retaining Ring Outer Piston Inner piston Screw Stat o seal Spring Outer Piston Seal O Ring Screw Washer Seal Retainer Quad Ring Ball Spring O Ring Spacer Seal O Ring Seal O Ring FUNCTION Retain piston assembly against spring force Regulate outlet pressure Isolate working fluid from reference fluid Holds inner and outer pistons together Used in conjunction with screw item 4 Provides biasing value between reference pressure and outlet pressure Isolate outlet from inlet when unit is locked out To energize seal item 7 Holds item 11 seal retainer in place Used in conjunction with item 9 screw Retains Inner piston seals and spacers To provide sealing seat for ball item 13 To isolate inlet and outlet during lock out Provides biasing value between outlet pressure and inlet pressure To provide sealing seat for outer piston item 2 To provide segregation between the two sets of seal O ring item 17 and 18 Isolate working fluid from reference fluid To energize seal item 17 To prevent external leakage To energize seal item 19 FAILURE MODE Broken missing or loose Broken scratched or
36. or 12A be below 0 245 inches 6 223 mm diameter over replaced upon every overhaul more than 50 of its length The ends may be 72 Inspect all metal parts for dings gouges chamfered to remove any tool marks caused by brasi tc Use 320 arit ar d th the removal operation The chamfering should ELI QUSE grit paper DO not extend for a length of more than 0 250 and remove sharp edges Replace any part with inches 6 350 mm damage exceeding 15 of local wall thickness i Use alodine 1200 to touch up bared aluminum e Check Pin 17 for damage or cracks Roll on Precisely measure the following items Replace a flat surface to check for straightness Replace any part that exceeds the identified maximum or any suspect pin minimum wear limits e Measure diameter of the two groups of three e The hole in Shaft Assembly 38 shall not larger holes in Plate 14 If larger holes are exceed 0 317 inches 8 052 mm in diameter elongated or exceed 0 253 inches 6 426 mm i Check the looseness inthe riveted diameter or the smaller ones are elongated or exceed 0 222 inches 5 639 mm the Plate 14 attachment of the Shaft Assembly 38 DEO should be replaced Maximum looseness of this joint shall not exceed 0 013 inches 330 mm Check Measure the main diameter of the Crank looseness by holding threaded end in a vise 37 It shall not be less than 493 inches push link end toward threaded end to its stop 12 560 mm and lightly scribe a l
37. rface Wave Washers Provides seal between Body and Bushing Prevents Crank from separating from Crank Shaft Connects poppet to Crank handle assembly In Line with valve link Connects Poppet Valve to crank assembly in line with shaft Holds all components together Provides access for applying pressure gauge or other accessories FAILURE MODE Missing or broken Bent shaft Broken shaft Broken locking lug Missing or broken Missing or broken Missing or broken Worn or gulled Missing or broken Missing Missing or broken Missing or broken Missing Missing or broken Broken Bent Broken Bent Installed backwards Cracked Missing SM60427 RESULT OF FAIL None Difficulty in use binding 1 Poppet valve opens cannot stop fuel flow 2 Crank handle may come off and release fuel Possible to rotate collar while refueling nozzle separates massive fuel spill Premature wear between operating handle and bushing Spacer Precaution to prevent premature unthreading of the bushing Non functional Fuel leaking Fuel leaking Fuel Spray Additional play between nozzle body and operating handle None Fuel Spray 1 Crank may loosen and prevent complete fuel shutoff Poppet valve opens cannot stop fuel flow Difficult to open or close valve Poppet valve fails open cannot stop fuel flow Difficult to open or close valve Cannot open val
38. risk assessment procedure based upon the hazard probability as well as hazard severity may be required to establish priorities for corrective action and resolution of identified hazards One example is the real hazard index a numeric rank ordering of a mathematical combination arrived at by assigning numerical values to the severity category and probability level A Hazard Probability The probability that a hazard will occur during the planned life expectancy of the system can be described in potential occurrences per unit of time event population item or activity Assigning a quantitative hazard is generally not possible early in the design process A qualitative hazard probability may be derived from research and evaluation of historical safety data from similar systems Level Descriptive word Specific Individual Item Fleet or Inventory E 2 F 1 B Frequent Likely to occur frequently Continuously experienced Reasonably probable Will occur several times in life of an item Will occur frequently Occasional Likely to occur sometimes in the life of an item Will occur several times Remote So unlikely it can be assumed that this hazard Unlikely to occur but possible will not be experienced Extremely Improbable Probability of occurrence cannot be So unlikely it can be assumed that this distinguished from zero hazard will not be experienced Impossible Physically impossible to occur Physically impossible Hazard Severity Hazard
39. rospace Group Fluid amp Electrical Distribution Division 9650 Jeronimo Road Irvine CA 92618 Ph 949 452 9500 Fax 949 452 9992 E TN Powering Business Worldwide
40. severity categories are defined to provide a qualitative measure of the worst potential consequences resulting from personnel error environmental conditions design inadequacies procedural deficiencies or system subsystem or component failure malfunction Severity Category Descriptive word Results 4 Catastrophic May cause death or system loss Il 3 Critical May cause severe injury or system damage 2 May cause minor injury minor occupational illness or minor system damage IV 1 Negligible Will not result in injury occupational illness or system damage Real Hazard Index RHI Matrix RHI Hazard Severity X Probability Level HAZARD SEVERITY 4 I 3 I 2 IV 1 A 6 24 18 12 6 B 5 20 15 10 5 PROBABILITY C 4 16 12 8 4 LEVEL D 3 12 9 6 3 E 2 8 6 4 2 F 1 4 3 2 1 General guidelines for required action RHI 1 8 No action required 9 12 Special precautions required investigate redesign 13 24 Hazardous redesign necessary or procedural control if redesign is impractical 20 11 8 NR 6A 6B 6C 6D 6E 6F 6G SM60427 May 2013 FAILURE MODES AND EFFECTS ANALYSIS FMEA Refer to Figure 5 for component numbers mentioned in column one COMPONENT Cover Assembly Handle Nut 2 Handle Bolt 2 Handle Washer 2 10 Handle Assembly 15 Handle Assembly Handle Stirrup Handle Grip 2 Handle Grip Washer 2 Handle Grip
41. tions Carter Model 60427 Underwing Refueling Nozzle May 2013 1 0 INTRODUCTION This manual furnishes detailed instructions In this latest issue the new part numbering covering the maintenance and overhaul of System required to identify the nozzle is also Eaton s Carter ground fueling equipment fully explained See Section 3 0 product line Model 60427 Underwing Refueling Nozzle and its various options For the Model 60427 nozzle IS designed to mate all maintenance of options to the basic 60427 international standard aircraft adapters made in nozzle refer to Options Table Section 3 0 This accordance with 524484 529514 or table will reference the service manual that equivalent should be used in the maintenance of each option 2 0 EQUIPMENT DESCRIPTION Model 60427 nozzle is a 2 1 2 inch underwing model number 60427 which would include the refueling nozzle It is designed for use with all standard handle grips and nose seal Other grades of commercial and military jet fuels Its options that are available to build a nozzle to operating pressure range is 0 200 psi with a specific specifications are listed in the table rated flow of 600 gpm The nozzle will have a shown in Section 3 0 The exploded view figure pressure drop of approximately 3 psi at rated 2 includes options D E amp T Other available flow when fully opened The operating options are either shown in the other exploded temperature range is 35 F to 1
42. ve fully 1 Fuel leak 2 Difficulty in attaching to aircraft Massive fuel spill 23 HAZARD CATEGORY V 1 V 1 4 4 4 V 1 V 1 V 1 V 1 4 V 1 V 1 4 4 4 2 4 2 V 1 4 V 1 4 HAZARD PROBABILITY REAL HAZARD INDEX 12 12 12 12 12 12 12 2013 CORRECTIVE ACTION Replace Lock Washer Replace Crank Handle 1 Pressure test prior to use 2 Shut off fuel at source Same as above Prior to refuel verify integrity by attempting to rotate collar with handle open and nozzle attached to aircraft Replace Washer Replace Wire Lock Replace Bushing Replace Spacer Pressure test prior to use Replace Wave Washer Replace Washer Pressure test prior to use Replace Cotter Pin 1 Pressure test prior to use 2 Shut off fuel at source Same as above Same as above Same as above 1 Pressure test prior to use 2 Visual Inspection Same as above SM60427 May 2013 12 0 12 1 12 2 FAILURE MODES AND EFFECTS ANALYSIS HOSE END CONTROL VALVE Notes that apply to this analysis A Hazard category hazard probability and real hazard index RHI are defined herein B Visual inspection means examining the regulator for obvious cracks damage and broken lugs prior to initial pressurization C Pressure test prior to use means pressuri
43. when a male half from part 3 or option R is specified di To obtain a nozzle with two regulators specify two options in series F5F4 results in 55 and 45 psi units with the 55 psi unit assembled as the one nearest the inlet It should also be noted that the 555 version of the hose end regulator no longer exists it has been replaced by the F5 The 555 was a 55 psi unit with a gold anodized body for identification All F5 regulators have a gold alodined stripe around the body pee Can be used only with any option F Can not be used with options 3 5 or 7 9 from part 3 below PART 3 One of the numbers on the following page must be included as part 3 as indicated above to specify the type of inlet configuration desired The nozzle may be ordered with the inlet terminating in an adapter half only if desired In this case leave Part 4 blank If a female half either quick disconnect or dry break of some configuration is desired Part 4 must be completed Option Description Option Description Letter Letter 3 Adds ball valve Model 64015 Refer to catalog 4 Adds male adapter half to mate 64001 swivel sheet 64015 for more details to order and or quick disconnect when the regulator is used options available any F option 44185 3D Adds glass inspection port to ball valve 5 Adds male adapter half to mate 64001 swivel quick disconnect when used without regulator any F option 44700 3E Adds drag ring to
44. zing the regulator to operating fuel pressure then removing pressure prior to aircraft arrival D Shut off fuel at source will be the first action for any leak To further improve operating safety this procedure should be used for all refueling operations In addition fuel flow should be turned on at the source not at the nozzle E Item numbers referred to in this section are those used in Figure 1 RISK ASSESSMENT A risk assessment procedure based upon the hazard probability as well as hazard severity may be required to establish priorities for corrective action and resolution of identified hazards One example is the real hazard index a numeric rank ordering of a mathematical combination arrived at by assigning numerical values to the severity category and probability level A Hazard Probability The probability that a hazard will occur during the planned life expectancy of the system can be described in potential occurrences per unit of time event population item or activity Assigning a quantitative hazard is generally not possible early in the design process A qualitative hazard probability may be derived from research and evaluation of historical safety data from similar systems Level Descriptive word Specific Individual Item Fleet or Inventory 6 5 4 3 gt 2 F 1 Frequent Likely to occur frequently Continuously experienced Reasonably probable Will occur several times in

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