F116 + Rev 1.2 2003-07-15 Underwing Refueling Nozzle

Maintenance Manual
UNDERWING REFUELING NOZZLE

F116 SERIES
NOTICE: PROPRIETARY INFORMATION OF WHITTAKER CONTROLS, INC., A BUSINESS UNIT OF MEGGITT PLC. THE INFORMATION CONTAINED IN THIS DOCUMENT IS DISCLOSED IN CONFIDENCE. IT IS THE PROPERTY OF WHITTAKER CONTROLS, AND SHALL NOT BE USED, DISCLOSED TO OTHERS, OR REPRODUCED IN WHOLE OR IN PART WITHOUT THE EXPRESS WRITTEN CONSENT OF WHITTAKER CONTROLS. IF CONSENT IS GIVEN THIS NOTICE SHALL APPEAR IN ANY SUCH REPRODUCTION.
REVISION 1.2 07/15/2003
WHITTAKER CONTROLS, INC.

A MEGGITT PLC COMPANY MAINTENANCE MANUAL
UNDERWING REFUELING NOZZLE F116 SERIES
LIST OF EFFECTIVE PAGES

On a revised page, the portion of text or illustrations affected by the change is indicated by a vertical line in the outer margin of the page. When a revision is issued, the entire document is reissued with the current revision number and date shown on all pages. For major revisions, the basic number is incremented. For minor revisions, the number following the decimal is incremented. Dates of issue for original and subsequent revisions are as follows: Original 1.0 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11/01/2001 Revision 1.1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 02/15/2002 Revision 1.2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 07/15/2003
The total number of pages in this technical document is 30 consisting of the following: Title, A, 1 28
TABLE OF CONTENTS
SUBJECT PAGE
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 Description and Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 Special Tools and Test Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Fault Isolation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Repair Tasks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 Illustrated Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
GROUND FUELING PRODUCTS GROUP
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INTRODUCTION
1. General This manual provides component maintenance shop instructions for the Underwing Refueling Nozzle (nozzle). 2. Revision Service This manual will be revised as necessary to show the current information. 3. Weights and Measurements Weights and measurements in this manual are expressed primarily in English (U.S. customary) and selected Metric (SI) units.
DESCRIPTION AND OPERATION

1. Description The Underwing Refueling Nozzle (nozzle) (see Figure 1) provides the means of controlling the flow of fuel in pressure fueling operations. The nozzle inlet port couples to a fueling hose. The outlet port attaches to the inlet adapter of the system being fueled. The nozzle provides a leakproof connection between the system being fueled and the fuel supply. 2. Operation A. Uncoupled When the nozzle is not coupled to a mating fuel system inlet adapter, its poppet valve is closed, so that there is no flow or leakage of fuel from the outlet port. The flow control handle that operates the poppet valve remains locked in the CLOSED position until the nozzle is coupled to the mating fuel system inlet adapter.
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Figure 1. Underwing Refueling Nozzle B. Coupling and Opening When the nozzle is coupled to the mating fuel system inlet adapter, the nose seal of the nozzle is compressed against the sealing surface of the inlet adapter to form a fluid-tight connection. When the nozzle is fully engaged and locked to the bayonet flange of the inlet adapter, the flow control handle is unlocked. Rotation of the flow control handle to the OPEN position opens the poppet valve, providing a flow passage into the system being fueled. As the system is being fueled, fuel pressure acts on the floating nose seal of the nozzle to increase the sealing force. C. Closing and Uncoupling Rotation of the flow control handle to the CLOSED position closes the poppet valve and the flow passage into the system being fueled. When the nozzle is unlocked and disengaged from the bayonet flange of the inlet adapter, the flow control handle is locked in the CLOSED position.
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D. Adapters Suitable attachment adapters such as swivels and/or hose end control valves (HECV) may be used to adapt the nozzle to any fuel system. 3. Leading Particulars (Refer to Table 1) Table 1. Leading Particulars Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Automotive and Aviation Fuels Operating Pressure (maximum) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120 psi (8,2 bar) Fluid Temperature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40 to 165F (54 to 74C) Ambient Temperature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40 to 165F (54 to 74C) Mating Inlet Flanges . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F574/F594 HECV, F575/F584, F577/F582, F581 Swivels, F596 Dry Disconnect
4.
Model Variations The basic F116 series nozzle is a straight-in fueling nozzle with a flanged inlet designed to mate with various swivel types. It is equipped with replaceable bicycle grip handles and a dust cover. A swivel is not supplied with the basic nozzle, but can be ordered as a variation. Refer to Tables 2, 3 and 4 for the available F116 series nozzle variations. Many variations are available. An explanation of the F116 series part numbering system is shown below:
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Table 2. Nozzle Variations (Mod Code Group After F116) Examples: F116A2A, F116BCHM2A
NOZZLE MOD LETTER
DESCRIPTION
A B C D F G H J K L M N P Q R
Adds grounding cable Adds vacuum breaker Replaces bicycle handles with stirrup handles Replaces standard length handles with 10-inch long handles Adds 2-inch ANPT female threaded inlet Adds 45 psi (310 kPa) HECV Adds 35 psi (241 kPa) HECV Replaces standard connector with replaceable wear points Adds adapter for J. C. Carter inlet flange Adds 50 psi (345 kPa) HECV Adds 0 to 100 psig pressure gage Replaces standard nose seal with flexible nose seal Adds 55 psi (379 kPa) HECV Adds 45 adapter for MS33786-40 2-inch inside diameter flange Adds grounding cable, 100 mesh strainer, and 2-inch (63,5 mm) coupling with 2-inch (50,8 mm) female cam lock inlet Adds grounding cable, 100 mesh strainer, and 2-inch (63,5 mm) coupling with 4inch (101,6 mm) female cam lock inlet Adds 40-mesh strainer suitable for the coupling type Adds 60-mesh strainer suitable for the coupling type Adds 100-mesh strainer suitable for the coupling type
T U V
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Table 2. Nozzle Variations (Mod Letter Group After F116) (continued) Examples: F116A3A, F116BCHM3A
NOZZLE MOD LETTER
DESCRIPTION
W X Y Z
Adds adapter for MS33786-40 (2-inch) inside diameter flange Replaces standard body with heavy duty type with replaceable nose. Adds 3/8-inch BSPPL port in body (open, not plugged) Adds 3/8-inch ANPT port in body (plugged)
Table 3. Coupling Variations (Type Number Between the Mod and Type Letter Groups) P/N Examples: F116A2A, F116BCHM6A
COUPLING TYPE NUMBER
DESCRIPTION
Bronze coupling (2-inch) to mate with F501, F577, F582 swivel body (uses 2inch strainer). (When replacing strainer, use F582E7.) Standard 3-inch aluminum coupling with corrosion resistant steel wire races to mate with F575/F584 swivel body (uses 3-inch strainer) Standard 3 inch aluminum coupling with corrosion resistant steel wire races to mate with F575/F584 swivel body (uses 3-inch strainer) Bronze coupling to mate with flight refueling swivel body Bronze coupling to mate with F575/F584 swivel body (uses 3-inch strainer) Standard 2-inch aluminum coupling with corrosion resistant steel wire races to mate with F577/F582 swivel body (uses 2-inch strainer) Aluminum coupling (2-inch) with heavy duty steel ball race (uses 2-inch strainer). (When replacing strainer, use F582E7.)
5 6 7
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Table 4. Swivel Body Inlet Variations (End Type Letter) P/N Examples: F116A4A, F116BCHM7F
SWIVEL BODY TYPE LETTER
DESCRIPTION
A B C D E F
2-inch ANPT inlet. Available for coupling types 3, 4 or 7 only. 2-inch BSPPL inlet. Available for coupling types 3, 4 or 7 only. 3-inch ANPT inlet. Available for coupling types 3, 4 or 7 only. 2-inch ANPT inlet. Available for coupling types 3, 4 or 7 only. 3-inch BSPPL inlet. Available for coupling types 3, 4 or 7 only. 3-inch National Valve type end connection. Available for coupling types 3, 4 or 7 only. 3-inch BSPPL inlet. Available for coupling type 7 only. 4-inch ANPT inlet. Available for coupling type 7 only. 2-inch female Camlock inlet. Available for coupling type 7 only. 4-inch female Camlock inlet. Available for coupling type 7 only. 3-inch ANPT inlet. Available for coupling type 7 only. 2-inch BSPPL inlet. Available for coupling type 7 only.
G K T U V X
5.
Model Equivalents Table 5 is a matrix showing substitution equivalency of earlier F100/F110/F115 series nozzles with current production F116 series replacement nozzles.
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Table 5. F116 Series Replacements for Earlier Series Nozzles
F100/F110/F115 NOZZLE PART NUMBERS F116 REPLACEMENT NOZZLE PART NUMBERS
F100/F110/F115T2A F100ABDN/F110ABDN/F115ABV3D F100D/F110D/F115T2D F100DN/F110DN/F115V2D F100N/F110N/F115V2A F115ABV3D F115T3A F115T3D F115V3A F115V3D
F116T7A (2-inch diameter coupling and strainer) F116ABV7D (2-inch diameter coupling and strainer) F116T7D (2-inch diameter coupling and strainer) F116V7D (2-inch diameter coupling and strainer) F116V7A (2-inch diameter coupling and strainer) F116ABV3D* (3-inch diameter coupling and strainer) F116T3A* (3-inch diameter coupling and strainer) F116T3D* (3-inch diameter coupling and strainer) F116V3A* (3-inch diameter coupling and strainer) F116V3D* (3-inch diameter coupling and strainer)
*Indicates functionally equivalent F116 series nozzles that are not completely interchangeable with the earlier models, since they differ in the disconnect area, having 3-inch diameter couplings and strainers.
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SPECIAL TOOLS AND TEST EQUIPMENT

1. General Special tools and test equipment recommended for maintenance of the nozzle are listed in Table 6. Table 6. Special Tools and Test Equipment
PART NUMBER DESCRIPTION APPLICATION
C1-0-486 F65-0-1130 2706112-102 2706128-101 2872018 2872019 2872020 2872021
Hand Reamer Nose Seal Test Fixture Gage Assembly Gage, Adapter Wear Test Plug, 3-inch ANPT Test Plug, 3-inch BSPPL Test Plug, 2-inch ANPT Test Plug, 2-inch BSPPL
Alignment of the handle shaft bearings Leakage testing of the nose seal Adjustment of the nose seal Checking adapter wear Leakage testing of 3-inch NPT connections Leakage testing of 3-inch BSPPL connections Leakage testing of 2-inch NPT connections Leakage testing of 2-inch BSPPL connections
TESTING
1. General Perform all tests using Stoddard solvent (or equivalent) as the test fluid, supplied by a 0 to 120 psig test stand. 2. Functional Test A. B. Engage and lock the nozzle to the PORT C side of the test fixture (P/N F65-0-1130). Actuate the flow control handle five times. The valve must operate freely with no mechanical interference or binding. The flow control handle must rotate freely only when the nozzle is engaged and locked to the test fixture.
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3. Leakage Test A. B. C. Engage and lock the nozzle or the coupler to the PORT A side of test fixture (P/N F65-0-1130). Install a matching test plug in the inlet port of the nozzle under test. Actuate the flow control handle and fill the adapter and the nozzle with test fluid, bleeding out the air through the test plug in the nozzle. Open and close the nozzle three times at pressures of 5, 60 and 120 psig. Hold each test pressure for one minute minimum. There must not be any external leakage through the nozzle body, past the shaft seals, or the nose seal, or evidence of any damage to the nozzle. Rotate the flow control handle to its CLOSED position. Unlock and disengage the nozzle from the text fixture. Pressurize the nozzle to 5, 60 and 120 psig. Hold each test pressure for one minute minimum. There must not be any leakage from the exterior of the nozzle, or from the nose plug.
D.
E.
F.
G.
4.
Vacuum Breaker Test (F116B Only) A. Functional Test 1) Insert the vacuum breaker (46, IPL Figure 1) in the nozzle body (54, 55 or 56), or a suitable test fixture. Press the button (48) fully inward and then release it. The button must return to its normal position with no hang-up, chatter, or binding. The action must be free and smooth. Repeat this functional test three times.
2)
B.
Leakage Test 1) Pressurize the nozzle to 5, 60 and 120 psig. Hold each test pressure for one minute minimum. There must not be any leakage from the button end of the valve. DO NOT OVER-TIGHTEN POPPET (47), SINCE THIS MAY RESTRICT THE AIR FLOW.
CAUTION:
2)
If leakage is observed during testing, remove the vacuum breaker and examine the packing (49) for damage, and check for contamination under the poppet (47). If the packing is in good condition, tighten the poppet a small amount and repeat the test as necessary until leakage stops. If the packing (49) is damaged, replace it with a new packing. Then reassemble, and repeat all of the vacuum breaker tests.
3)
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FAULT ISOLATION
1. General Refer to Table 7 for fault isolation information. Locate suspected faulty component and take appropriate remedial action. Table 7. Fault Isolation
FAULT POSSIBLE CAUSE CORRECTIVE ACTION
Leakage at the poppet seat when closed
Damaged or worn seat (31, IPL Figure 1) Damage or worn poppet (25 or 26) Damaged or worn packing (30) Damaged or cracked nose on body (53, 54 or 55) Poppet (25 or 26) incorrectly adjusted
Replace the seat.
Replace the poppet.
Replace the packing. Replace the body.
Adjust the poppet.
Leakage past nose seal when coupled
Nose seal (28 or 67) damaged Mating flange and locking lugs on airplane fuel system inlet adapter damaged or worn
Replace the nose seal. Use the adapter wear gage (P/N 2706128-101) to check the three locking lugs of the bayonet flange for wear, straightness, and alignment. If they are damaged, the airplane inlet adapter must be replaced. Adjust the poppet.
Nozzle engages too tightly
Poppet (25 or 26) incorrectly adjusted Packing (37 or 38) damaged, twisted, or incorrectly installed Bearing (59 or 60) damaged or worn
Leakage past flow control handle shaft
Replace the packings.
Replace the bearings.
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REPAIR TASKS
1. Lubrication Lightly lubricate all of the packings with petrolatum prior to installation. 2. Removing the Poppet (25 or 26, IPL Figure 1) A. B. C. D. 3. Remove the dust cap (5) from the nozzle. Compress the key ring (22) and rotate the shell grips (16). Rotate the flow control handle (34) to its OPEN position. Remove the cotter pin (24) and unscrew the poppet (25 or 26).
Adjusting the Poppet (25 or 26, IPL Figure 1) A. B. Remove the poppet (25 or 26) in accordance with paragraph 1 above. Initial Adjustment With the flow control handle (34) at its fully OPEN position, screw the poppet (25 or 26) onto the rod (44) until the flow control handle cannot be rotated to its CLOSED position. Back the poppet outward until the flow control handle can just be rotated to its CLOSED position. Back the poppet out further, up to -turn, to align the holes for the cotter pin (24). C. Checking the Poppet Adjustment 1) Insert the flange of the nose seal adjustment gage (P/N 2706112-102) in the nozzle and rotate the handles (10, 11, 12 or 13) to the connected position. The flow control handle (34) must remain in the closed position. Insert plug of the nose seal adjustment gage (P/N 2706112-102) in the nozzle. If the poppet adjustment is correct, the flange level will be between the surface marked "BELOW FLANGE" and the gage surface marked "ABOVE FLANGE." If the poppet adjustment is not correct, screw it inward or outward until it is correct, and then align the slot to install the cotter pin (24)
2) 3)
D.
Install and form the cotter pin (24) to retain the poppet (25 or 26).
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4. Replacing the Nose Seal Seat (31, IPL Figure 1) A. B. Remove the poppet (25 or 26) in accordance with paragraph 1 above. Using two screwdrivers opposite each other, gently ease nose seal seat (31) from the nozzle body (54, 55 or 56), using connector (17 or 20) as the fulcrum for the screwdrivers. Check the nozzle body (54, 55 or 56) and the Belleville washer (32) for damage or excessive wear. Lubricate the packing (30) with petrolatum. Install the packing in the packing groove of the new nose seal seat (31). Install the new nose seal seat and the Belleville washer (32) in the nozzle body (54, 55 or 56). The convex side fo the Belleville washer (32) must be toward the nose of the nozzle as shown in IPL Figure 1 to operate correctly.
C.
D.
NOTE:
5.
Replacing the Nose Seal (28, IPL Figure 1) A. Rotate the flow control handle (34) to its fully OPEN position to relieve tension on the nose seal (28). Carefully remove the spring (27) from the retainer (29). Using a screwdriver, gently pry the retainer (29) off of the nose seal seat (31), with the nose seal (28) installed. Remove the nose seal (28) from the retainer (29). Do not lubricate the new nose seal (28). Install the nose seal in the seal groove of the retainer (29). Lightly lubricate the inside diameter of the nose seal (28) with petrolatum. Do not allow the petrolatum to get between the seal and the retainer (29). Install the nose seal (28) and the retainer (29) on the nose seal seat (31) so that inner protrusion of its rubber rests on the lip of the seat. An old bayonet adapter flange can be used to install the nose seal..
B. C.
D. E.
F.
G.
NOTE: H.
Use a flat plate to apply even pressure on the nose seal (28). The nose seal will snap into place on the nose seal seat (31).
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CAUTION: THE POPPET SPRING (27) MUST NOT EXTEND BEYOND THE OUTSIDE DIAMETER OF THE RETAINER (29). THE ENDS OF THE SPRING MUST PASS THROUGH HOLES IN THE RETAINER AND ENTER GROOVE OF THE NOSE SEAL SEAT (31). DO NOT OVERSTRETCH SPRING.
I. 6.
Insert the ends of the poppet spring (27) through holes in the groove of the retainer (29).
Replacing the Nose Seat-Seal (67, IPL Figure 1) A. B. Remove the poppet (26 or 27) in accordance with paragraph 1 above. Using the special screwdriver (P/N 2707013), gently pry outward and downward on the Belleville retainer (30), starting at one end and working around until it is free of the nesoe-seal seat (29). Remove the nose seal-seat from the nozzle body (53, 54 or 55). Check the nozzle body (53, 54 or 55) and the Belleville washer (31) for damage or excessive wear. Check the Belleville retainer (30) for roundness or deformation. The Belleville retainer can be reformed to its round shape by hand. The convex side fo the Belleville washer (31) must be toward the nose of the nozzle as shown in IPL Figure 1 to operate correctly.
C.
NOTE:
D.
Install the Belleville retainer (30) and the Belleville washer (31) on the new nose seal-seat (29). The Belleville retainer should be round and should fit snugly on the nose seal-seat. Lubricate the packing (28) with petrolatum. Install the packing in the packing groove of the nose seal-seat. Do not over-bend the Belleville retainer (30) during installation. The Belleville retainer must fit snugly against the nozzle body (53, 54 or 55), with its lower lip in the groove of the nozzle body. The nose seal-seat (29) must not be loose en the nozzle body.
CAUTION:
E.
Install the new nose seal-seat (29) with the Belleville retainer (30) and the Belleville washer (31) in the nozzle body (53, 54 or 55). Gently pry the Belleville retainer into its groove in the body, starting at one end and working around until it is fully engaged with the nose seal-seat and the nozzle body.
7.
Replacing the Stop Screws (57, IPL Figure 1) A. Remove the nuts (7), the washers (8), the bolts (9) and the handles (10, 11, 12 or 13) from the shell grips (16). Remove the screws (14), the washers (15) and the shell grips (16) from the connector (17 or 20). Remove the screws (57) and the split ring (58) from the nozzle body (54, 55 or 56).
B. C.
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D. Inspect the key ring (22) and the shell grips (16). The wear surfaces must be smooth and free of gouges or pits which could cause tight engagement. Replace these parts if they are damaged. The key ring and the shell grips can be sprayed with dry-film lubricant. Do not use grease on these parts. Install the split ring (58) and the new screws (57) on the nozzle body (54, 55 or 56). Use a single strand of lockwire to safety wire the screws. Carefully tuck in the ends of the lockwire to prevent interference with the shell grips. Make sure that the springs (23) and th key ring (22) are correctly positioned. Install the shell grips (16) and secure them to the connector (17 or 20) with the screws (14) and the washers (15). Safety wire the screws with lockwire. Install the handles (10, 11, 12 or 13) in the shell grips (16). Secure the handles with the nuts (7), the washers (8) and the bolts (9).
E.
F.
G.
8.
Replacing the Handle Shaft Packings (37 and 38, IPL Figure 1) A. Rotate the flow control handle (34) to its fully OPEN position to relieve tension on the nose seal (28). Remove the cotter pin (24) and the washer (36) from the small end of the handle shaft (39). Note the orientation of the crank (42) with respect to the flow control handle (34), for reassembly reference.
B.
NOTE:
C.
Slowly pull the handle shaft (39) (with flow control handle attached to it) out of the nozzle body (54, 55 or 56), and push a small rod or screwdriver in from the opposite end to retain the linkage. If linkage becomes uninstalled, refer to paragraph 7G, steps 1 through 6 below. Remove the small packing (37) from the handle shaft (39) and large packing (38) from the nozzle body (54, 55 or 56) using a suitable pointed tool. Reinstall the flow control handle (34) and the handle shaft (39) in the nozzle body (54, 55 or 56) with no packings or washers under the handle, but with the washers (35 and 36) and the cotter pin (24) installed. Using suitable feeler gages, measure the end play of the handle shaft (39). If the end play is more than 0.015 inch remove the handle shaft and add washers (35 or 36) as required to reduce end play to less than 0.015 inch. MAKE SURE THAT THE PACKINGS ARE NOT TWISTED WHEN THEY ARE INSTALLED IN THE PACKING GROOVES. LUBRICATE THE PACKINGS WELL WITH PETROLATUM TO AVOID DAMAGING THEM DURING INSTALLATION.
D.
E.
F.
CAUTION:
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G. Install the small packing (37) on the handle shaft (39) and large packing (38) in the nozzle body (54, 55 or 56), behind the bearing (59), using a pair of tweezers or similar suitable tool. Insert the handle shaft (39) with an easy twisting motion, slowly withdrawing the small rod or screwdriver. If the crank (42) and links (43) became uninstalled, proceed as follows: Line up the links (43) so that their curved sides match the bulge in the side of the nozzle body (54, 55 or 56). Insert the handle shaft (39) with a twisting motion until it enters the crank (42) up to its hexagonal section. Rotate the flow control handle (34) so that it points 90 degrees from the center of the nozzle body (54, 55 or 56) in the OPEN position. Pull the crank (42) upward from inside of the nozzle body (54, 55 or 56) allowing the crank to hang vertically. Slide the handle shaft (39) inward so that its hexagonal section enters the crank (42). Push the handle shaft (39) into its fully installed position.
H.
NOTE: 1)
2)
3)
4)
5) 6) I.
Rotate the flow control handle to its OPEN position. Make sure that the linkage operates freely and correctly.
9.
Replacing the Clevis Pins (41, IPL Figure 1) and the Links (43) A. B. C. Remove the poppet (25 or 26) in accordance with paragraph 1 above. Remove the cotter pins (24) and the clevis pins (41). Remove the shaft and linkage assembly (items 24, 41, 42, 43 and 44) from the nozzle body (54, 55 or 56). Install the new links (43) and secure them with new clevis pins (41) and new cotter pins (24). Install the linkage and shaft assembly in the nozzle body (54, 55 or 56). Adjust the poppet in accordance with paragraph 3 above.
D.
E.
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10. Replacing the Bearings (59 and 60, IPL Figure 1) CAUTION: DO NOT CLAMP THE NOZZLE BODY TOO TIGHTLY OR IT MAY BECOME DEFORMED OR CRACKED.
A.
Carefully clamp the nozzle body (54, 55 or 56) in a vise, so that the handle shaft boss faces upward. Using a 9/16-12NC tap, form three to four threads in the bearing (59) (just sufficient to grip the bearing). Thread a bolt into the bearing (59) and insert a rod into the hole in its other end. Gently tap the rod until bearing is removed. Remove the bearing (60), using a 7/16-14NC tap in a similar manner. Blow out all machining chips from the interior of the nozzle body (54, 55 or 56) with compressed air. Carefully press new bearings (59 and 60) into the nozzle body (54, 55 or 56), tapping them lightly with a plastic or rubber (not steel) mallet until they are fully shouldered. Check the alignment of the bearings (59 and 60) using the handle shaft (39) with no packings installed. Rotate the handle shaft several times to check for binding. If necessary, use the hand reamer (P/N C1-0-486) to align the bearings.
B.
C.
D. E.
F.
G.
11. Replacing the Insert (71, IPL Figure 1) A. B. Remove the poppet (25 or 26) in accordance with paragraph 1 above. Using two screwdrivers opposite each other, gently ease nose seal seat (31) from the nozzle body (54, 55 or 56), using connector (17 or 20) as the fulcrum for the screwdrivers. Check the nozzle body (54, 55 or 56) and the Belleville washer (32) for damage or excessive wear. Remove the nuts (7), the washers (8), the bolts (9) and the handles (10, 11, 12 or 13) from the shell grips (16). Remove the screws (14), the washers (15) and the shell grips (16) from the connector (17 or 20). Remove the screws (57) and the split ring (58) from the nozzle body (54, 55 or 56). Remove the packing (70) and the insert (69) from the nozzle body (54, 55 or 56).
C.
D.
E. F. G.
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H. I. Install the new insert (69) and packing (70) in the nozzle body (54, 55 or 56). Install the split ring (58) and the new screws (57) on the nozzle body (54, 55 or 56). Use a single strand of lockwire to safety wire the screws. Carefully tuck in the ends of the lockwire to prevent interference with the shell grips. Make sure that the springs (23) and th key ring (22) are correctly positioned. Install the shell grips (16) and secure them to the connector (17 or 20) with the screws (14) and the washers (15). Safety wire the screws with lockwire. Install the handles (10, 11, 12 or 13) in the shell grips (16). Secure the handles with the nuts (7), the washers (8) and the bolts (9).
J.
K.
CLEANING
1. Cleaning Materials Refer to Table 8 for recommended cleaning materials. Suitable equivalent cleaning materials may be substituted for the items listed. Table 8. Recommended Cleaning Materials
DESCRIPTION SPECIFICATION SOURCE
Brush, Bristle, stiff, nonmetallic Dry Cleaning Solvent Pick, Teflon Plastic Bags Tissues, lint-free
P-D-680, Type 2
Commercially available Commercially available Commercially available Commercially available Commercially available
2.
Cleaning Procedures WARNING: DRY CLEANING SOLVENT IS FLAMMABLE AND TOXIC TO EYES, SKIN, AND RESPIRATORY TRACT. SKIN/EYE PROTECTION REQUIRED. AVOID REPEATED/ PROLONGED CONTACT. USE ONLY IN WELL VENTILATED AREAS. GOOD GENERAL VENTILATION IS NORMALLY ADEQUATE. KEEP AWAY FROM OPEN FLAMES OR OTHER IGNITION SOURCES.
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A. Clean all metal parts by washing thoroughly in dry cleaning solvent. Remove stubborn deposits by scrubbing with a nonmetallic stiff bristle brush. Brush all threaded areas. Use a Teflon pick to remove obstructions from the ports, the seal or packing grooves and the flow passages. Make sure that the flow passage of the nozzle body (54, 55 or 56, IPL Figure 1) is clean, especially where the plug (45) is installed. , All of the parts must be free of corrosion, dirt, grease, oil, or any other foreign matter. WEAR EYE PROTECTION WHEN DRYING PARTS WITH COMPRESSED AIR. DO NOT DIRECT AIRSTREAM AT PERSONNEL OR LIGHT METAL PARTS.
B.
NOTE:
WARNING:
C. D.
Dry parts with clean lint-free tissues or clean, dry compressed air. Package clean parts in plastic bags.
INSPECTION
1. General A. Under strong light and magnification, visually check all parts in accordance with the general criteria specified in paragraph 2 below. Repair minor damage in accordance with instructions presented in the REPAIR section. If damage is major or beyond simple repair, replace the part rather than attempt extensive repairs.
B.
2.
Component Checks (Refer to Table 9) Table 9. Component Checks

DESCRIPTION (IPL Figure 1 Item No.)
CHECK CRITERIA
General
1) Visually check all parts as applicable for nicks, cracks, cuts, burrs, corrosion, breaks, scoring, deformation, dents, thread damage, or any other obvious defects. 2) Make sure that the ports, passages, recesses and sealing grooves are clean and unobstructed. 3) Check all sealing and seating surfaces for damage or corrosion which would affect sealing. 1) Check for burrs, excessive wear, and straightness. 2) Replace the screws if damaged. Do not attempt to repair them.
Machine Screws (9, 14, 52 and 57)
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Table 9. Component Checks (continued)
DESCRIPTION (IPL Figure 1 Item No.)
CHECK CRITERIA
Connector (17)
1) Using a dial indicator, check for wear on the lug engagement face in three places as shown in Figure 2, Sheet 1. If the wear is greater than 0.031 inch (0,78 mm), replace the connector. 2) Check the corner wear radius on the three corners as shown in Figure 2, Sheet 1. If any corner radius is worn to more than 0.078 inch (1,98 mm), replace the connector. 1) Using a dial indicator, check for wear on the lug engagement face in three places as shown in Figure 2, Sheet 2. If the wear is greater than 0.031 inch (0,78 mm), replace the connector. 2) Check the corner wear radius on the three setscrews as shown in Figure 2, Sheet 1. If any corner radius is worn to more than 0.062 inch (1,57 mm), replace the connector. 3) The face of the setscrew must be flush with the surface as shown in Figure 2, Sheet 2, within 0.005 inch (0,13 mm). (The setscrew can be replaced if damaged or excessively worn.) 1) If the free length of a spring is less than 0.850 inch (21,6 mm), replace the spring. 2) If a spring is not straight or is deformed, replace the spring. Check for sharp edges and abrasive wear. 1) The surface finish in the bearing areas must be smooth. 2) Roll the shaft on a flat surface to check straightness. The shaft must be straight. 3) Check for abrasive wear on the ends of the shaft. 4) Check for cracks at the cross holes. 1) Check the pin hole in the threaded end of the rad for cracks. 2) Replace the rod if cracks are found. 1) Check the shaft holes in the body for burrs where the packings enter. Remove any burrs. 2) Check for excessive wear of the sacrificial bosses at the handle shaft. 3) Check for cracks at all of the holes in the body. Replace the body if any cracks are found. 4) Check for cracks where the nose for the seat (31 or 67) joins the main body. Replace the body if any cracks are found. If the handle shaft (39) can be moved up and down more than 0.001 inch total, replace both of the bearings.
Connector (20)
Springs (23)
Flow Control Handle (34) Handle Shaft (39)
Rod (44) Nozzle Body (54, 55, 56 or 56A)
Bearings (58 and 60)
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Figure 2. Connector Wear Limits (Sheet 1 of 2)
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Figure 2. Connector Wear Limits (Sheet 2 of 2)
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ILLUSTRATED PARTS LIST

1. General This section lists, describes, and illustrates all detail parts required for maintenance support of the Underwing Refueling Nozzle. 2. Scope of Information A. The parts list is arranged in the general order of disassembly. The listing is indented to show the relationship between each part and its next higher assembly. Item numbers used in the parts list are keyed to the corresponding numbers of the accompanying illustration. MODIFICATION CODE The modification code indicates the parts usage with respect to the end item. When the MOD column is blank, the part usage is applicable to all versions unless otherwise specified in the DESCRIPTION column. C. How to Identify a Part 1) When the part number is known: Refer to the parts list for the item number, description, modification codes, and quantity. Refer to the illustration to verify the physical appearance and location of the part. When the part number is not known: Review the illustrations to identify the part by physical appearance and location. Refer to the accompanying parts list to obtain the part number, description, modification codes, and quantity.
B.
2)
D.
Abbreviations ASSY FIG. IPL MOD Assembly. Figure. Illustrated Parts List. Modification.
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IPL Figure 1. Underwing Refueling Nozzle (Sheet 1 of 2)
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IPL Figure 1. Underwing Refueling Nozzle (Sheet 2 of 2)
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FIG. ITEM
DESCRIPTION PART NUMBER 1 2 3 4 56 7
MOD CODES
UNITS PER ASSY
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31
CAN501D616-8 CMS35338-141 F62W7504 1426-595145 F62W7503 2671893 CMS20364-428C CMS35338-139 CAN4C13 1426-586133 1426-595133 F59F1377 F59F1378 CMS35275-265 MS35338-138 2671769 2662319 2682020 2682083 2682020-1 7-449-16 F61F1363 7410-585771 2706782-3-10 2713550-2 2713550-1 1426-585770 2662383-2 4631036 CMS29513-145 2701911
C SCREW, MACHINE . . . . . . . . . . . . . . . . . . C WASHER, LOCK . . . . . . . . . . . . . . . . . . . . C COVER ASSEMBLY, DUST . . . . . . . . . . . C C CABLE . . . . . . . . . . . . . . . . . . . . . . . . . . . C C COVER, DUST . . . . . . . . . . . . . . . . . . . . C CABLE, GROUNDING . . . . . . . . . . . . . . . . C NUT, SELF-LOCKING . . . . . . . . . . . . . . . . C WASHER, LOCK . . . . . . . . . . . . . . . . . . . . C BOLT, MACHINE . . . . . . . . . . . . . . . . . . . . C HANDLE, BICYCLE . . . . . . . . . . . . . . . . . . C HANDLE, BICYCLE (Long) (Replaces . . . . Item 10) C HANDLE, STIRRUP (RH) (Replaces . . . . . Item 10) C HANDLE, STIRRUP (LH) (Replaces . . . . . Item 10) C SCREW, MACHINE . . . . . . . . . . . . . . . . . . C WASHER, LOCK . . . . . . . . . . . . . . . . . . . . C GRIP, SHELL . . . . . . . . . . . . . . . . . . . . . . . C CONNECTOR . . . . . . . . . . . . . . . . . . . . . . C CONNECTOR ASSEMBLY (Replaces . . . . Item 17) C C SETSCREW . . . . . . . . . . . . . . . . . . . . . . C C CONNECTOR . . . . . . . . . . . . . . . . . . . . . C RING, SCUFF . . . . . . . . . . . . . . . . . . . . . . C RING, KEY . . . . . . . . . . . . . . . . . . . . . . . . . C SPRING, COMPRESSION . . . . . . . . . . . . . C PIN, COTTER . . . . . . . . . . . . . . . . . . . . . . C POPPET . . . . . . . . . . . . . . . . . . . . . . . . . . . C POPPET (For F110/F115 conversions . . . only) (Mates with 1426-585772 rod) C SPRING, POPPET . . . . . . . . . . . . . . . . . . . C SEAL (3 raised dots) . . . . . . . . . . . . . . . . . C RETAINER . . . . . . . . . . . . . . . . . . . . . . . . . C PACKING, PREFORMED . . . . . . . . . . . . . C SEAT, POPPET SEAL . . . . . . . . . . . . . . . .
1 1 1 1 1 1 2 2 2 2 2 1 1 6 6 2 1 1 3 1 1 1 3 4 1 1 1 1 1 1 1
D C C
J J J
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FIG. ITEM
MOD CODES
UNITS PER ASSY
32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 56A 57 58 59
2642886 219-1375HCP 4631059-2 CAN960PD816L CAN960C616L CMS29513-010 CMS29513-014 2633284 CAN960C516L CMS20392-4C29 2701173 2632214 F61F1307 2713659 CMS20913-3CR CMS20913-3CR F509 1429-595063 1429-586169 CMS29513-010 1429-586171 1429-595064 CMS35276-280 CMS35338-138 2681430-4 2681430-1 2681430-2 2681430-3 2681430-5 2662382 F61F1364 SLF517-10 FF620-7
C WASHER, BELLEVILLE . . . . . . . . . . . . . . . C PIN, SPRING . . . . . . . . . . . . . . . . . . . . . . . . C HANDLE, FLOW CONTROL . . . . . . . . . . . . C WASHER, FLAT . . . . . . . . . . . . . . . . . . . . . C WASHER, FLAT . . . . . . . . . . . . . . . . . . . . . C PACKING, PREFORMED . . . . . . . . . . . . . . C PACKING, PREFORMED . . . . . . . . . . . . . . C SHAFT, HANDLE . . . . . . . . . . . . . . . . . . . . . C WASHER, FLAT . . . . . . . . . . . . . . . . . . . . . C PIN, CLEVIS . . . . . . . . . . . . . . . . . . . . . . . . C CRANK . . . . . . . . . . . . . . . . . . . . . . . . . . . . C CRANK (Alternate) . . . . . . . . . . . . . . . . . . . . C LINK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C ROD, POPPET . . . . . . . . . . . . . . . . . . . . . . . C PLUG (1 required for 2681430-1 Body) . . . . C PLUG . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C BREAKER ASSEMBLY, VACUUM . . . . . . . (Replaces Item 45) C C POPPET . . . . . . . . . . . . . . . . . . . . . . . . . . C C BUTTON . . . . . . . . . . . . . . . . . . . . . . . . . . C C PACKING, PREFORMED . . . . . . . . . . . . . C C SPRING, COMPRESSION . . . . . . . . . . . . C C BODY, BREAKER . . . . . . . . . . . . . . . . . . . C SCREW, MACHINE . . . . . . . . . . . . . . . . . . . C WASHER, LOCK . . . . . . . . . . . . . . . . . . . . . C BODY ASSEMBLY, NOZZLE . . . . . . . . . . . C BODY ASSEMBLY, NOZZLE (Alternate) . . . C BODY ASSEMBLY, NOZZLE . . . . . . . . . . . C BODY ASSEMBLY, NOZZLE . . . . . . . . . . . C BODY ASSEMBLY, NOZZLE . . . . . . . . . . . C C SCREW, STOP . . . . . . . . . . . . . . . . . . . . . C C RING, SPLIT . . . . . . . . . . . . . . . . . . . . . . . C C BEARING . . . . . . . . . . . . . . . . . . . . . . . . . C C BEARING (Alternate) . . . . . . . . . . . . . . . . .
Z B B B B B B
1 1 1 1 1 1 1 1 2 2 1 1 2 1 2 2 1 1 1 1 1 1 6 6 1 1 1 1 1 3 1 1 1
M,Y M,Z X
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FIG. ITEM
MOD CODES
UNITS PER ASSY
60 61 62 63 64 65 66 67 68 69 70
SLF384-11 FF503-4 F594 F575/F584 F577/F582 F596 2706054 CMS20913-4 2713509 2671843 GTP1128A 2661058A038
C C BEARING . . . . . . . . . . . . . . . . . . . . . . . . . C C BEARING (Alternate) . . . . . . . . . . . . . . . . C VALVE, HOSE END CONTROL . . . . . . . . (Refer to Manual F594) C SWIVEL ASSEMBLY (3-inch strainer) . . . . (Refer to Manual F575) C SWIVEL ASSEMBLY (2-inch strainer) . . . . (Refer to Manual F575/F577) C DISCONNECT, DRY . . . . . . . . . . . . . . . . . C GAGE, PRESSURE (100 psi) . . . . . . . . . . C PLUG . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C SEAL, NOSE (Flexible) . . . . . . . . . . . . . . . C RETAINER . . . . . . . . . . . . . . . . . . . . . . . . . C INSERT, CONNECTOR . . . . . . . . . . . . . . . C PACKING, PREFORMED . . . . . . . . . . . . .
E,G,H,L
1 1 1 1 1 1 1 1 1 1 1 1
M Y,Z N N X X
NOZZLE OVERHAUL PARTS KITS AVAILABLE

KIT PART NUMBER APPLICABLE TO ITEMS IN KIT (IPL Figure 1)
KITF116-1 KITF116-3 KITF116-4 KITF116-5
F116 (Basic) F116 with F575/F584 swivel F116 with F577/F582 swivel F116 with F581 swivel
24, 27, 28, 30, 31, 33, 36, 37, 38 + 2661058A042 packing for inlet flange 24, 27, 28, 30, 31, 33, 36, 37, 38 + 2661058A042 packing for inlet flange + Q4235-366Y seal for swivel 24, 27, 28, 30, 31, 33, 36, 37, 38 + 2661058A042 packing for inlet flange + Q4231-366Y seal for swivel 24, 27, 28, 30, 31, 33, 36, 37, 38 + 2661058A042 packing for inlet flange + 2661058A042 packing and Q4235-366Y seal for swivel
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07/15/2003
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NOZZLE CONVERSION PARTS KIT AVAILABLE

KIT PART NUMBER APPLICABLE TO ITEMS IN KIT (IPL Figure 1)
KITF115-11*
F110 and F115
24, 26, 27, 28, 29, 30, 31 (The cotter pin hole in the rod must be drilled out to 0.096 inch diameter.)
*For conversion of the nose seal and poppet to the F116 type, using the existing rod (1426-585772) with 5/16-inch threads.
Revision 1.2
07/15/2003
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F116 + Rev 1.2 2003-07-15 Underwing Refueling Nozzle

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Maintenance Manual

UNDERWING REFUELING NOZZLE

REVISION 1.2 07/15/2003

WHITTAKER CONTROLS, INC.

UNDERWING REFUELING NOZZLE F116 SERIES

LIST OF EFFECTIVE PAGES

GROUND FUELING PRODUCTS GROUP

WHITTAKER CONTROLS, INC.

UNDERWING REFUELING NOZZLE F116 SERIES

DESCRIPTION AND OPERATION

GROUND FUELING PRODUCTS GROUP

WHITTAKER CONTROLS, INC.

UNDERWING REFUELING NOZZLE F116 SERIES

GROUND FUELING PRODUCTS GROUP

WHITTAKER CONTROLS, INC.

UNDERWING REFUELING NOZZLE F116 SERIES

GROUND FUELING PRODUCTS GROUP

WHITTAKER CONTROLS, INC.

UNDERWING REFUELING NOZZLE F116 SERIES

GROUND FUELING PRODUCTS GROUP

WHITTAKER CONTROLS, INC.

UNDERWING REFUELING NOZZLE F116 SERIES

GROUND FUELING PRODUCTS GROUP

WHITTAKER CONTROLS, INC.

UNDERWING REFUELING NOZZLE F116 SERIES

GROUND FUELING PRODUCTS GROUP

WHITTAKER CONTROLS, INC.

UNDERWING REFUELING NOZZLE F116 SERIES

GROUND FUELING PRODUCTS GROUP

WHITTAKER CONTROLS, INC.

UNDERWING REFUELING NOZZLE F116 SERIES

SPECIAL TOOLS AND TEST EQUIPMENT

C1-0-486 F65-0-1130 2706112-102 2706128-101 2872018 2872019 2872020 2872021

GROUND FUELING PRODUCTS GROUP

WHITTAKER CONTROLS, INC.

UNDERWING REFUELING NOZZLE F116 SERIES

GROUND FUELING PRODUCTS GROUP

WHITTAKER CONTROLS, INC.

UNDERWING REFUELING NOZZLE F116 SERIES

Leakage at the poppet seat when closed

Replace the seat.

Replace the poppet.

Replace the packing. Replace the body.

Adjust the poppet.

Leakage past nose seal when coupled

Nozzle engages too tightly

Leakage past flow control handle shaft

Replace the packings.

Replace the bearings.

GROUND FUELING PRODUCTS GROUP

WHITTAKER CONTROLS, INC.

UNDERWING REFUELING NOZZLE F116 SERIES

GROUND FUELING PRODUCTS GROUP

WHITTAKER CONTROLS, INC.

UNDERWING REFUELING NOZZLE F116 SERIES

GROUND FUELING PRODUCTS GROUP

WHITTAKER CONTROLS, INC.

UNDERWING REFUELING NOZZLE F116 SERIES