SM60554

January 2011

Applicable addition manuals:

Aerospace Group
Conveyance Systems Division
SM47076
UNDERWING
Carter® Brand FBO OPERATIONS
Ground Fueling Equipment
MODELS 64049
Carter now offers an underwing
airfield, FBO, use with a new ea
for strainer checking, with or
break. The underwing nozzle, a
utilizes the Carter Unisex Coupli

Maintenance & Repair Manual

Hydrant Valve
In Accordance With Bulletin API 1584

Model 60554

64049B2
Underwing Nozzle with
Unisex Coupling Inle
and Dust Caps for both

671 W. 17th St., Costa Mesa

BACK
TABLE OF CONTENTS
PAGE
1.0 INTRODUCTION ......................................................................................................................................3

2.0 EQUIPMENT DESCRIPTION ...................................................................................................................3

3.0 TABLE OF OPTIONS & ORDERING INFORMATION .............................................................................3

4.0 SAFETY INSTRUCTIONS/PREVENTATIVE MAINTENANCE.................................................................5

5.0 OPERATION.............................................................................................................................................6

6.0 DISASSEMBLY ........................................................................................................................................7

7.0 INSPECTION..........................................................................................................................................11

8.0 REASSEMBLY .......................................................................................................................................15

9.0 TEST ......................................................................................................................................................19

10.0 TROUBLESHOOTING............................................................................................................................20

11.0 ILLUSTRATED PARTS CATALOG ........................................................................................................20

FIGURE 1 - OPTIONS ........................................................................................................................................22

FIGURE 2 - UPPER HALF & OPTIONS A & B ...................................................................................................24

FIGURE 3 - 2-PIECE UPPER HALF ...................................................................................................................25

FIGURE 4 - LOWER HALF ASSEMBLY .............................................................................................................27

FIGURE 5 - LANYARD OPERATED PILOT VALVE ...........................................................................................29

FIGURE 6 - AIR OPERATED PILOT VALVES....................................................................................................31

FIGURE 7 - AIR/LANYARD OPERATED PILOT VALVE, OPTION F .................................................................33

FIGURE 8 - AIR/LANYARD OPERATED PILOT VALVE, OPTION U.................................................................35

FIGURE 9 - AIR/FUEL PILOT VALVE CONNECTOR ASSEMBLY – OPTION...................................................37

 SM60554 January 2011

Maintenance, Overhaul & Test Instructions

®
Eaton’s Carter Brand Model 60554 Hydrant Valve

1.0 INTRODUCTION

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

2.0 EQUIPMENT DESCRIPTION

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

• Lower Housing Assembly - functionally Various options are available to modify the basic
identical on the valves that are capable of flow in part number to customize the end item to meet
the fueling direction only. The "J" option uses a various customers’ requirements. These options
different assembly. The inlet flange, in all cases, are explained in detail in paragraph 3.0 below.

3.0 TABLE OF OPTIONS & ORDERING INFORMATION

There are seven basic valves to which various • 60554E - Air Operated Pilot Valve for
modifications may be added by option letters as deadman control. Valve allows flow in the
shown in the table below. The six basic units fueling direction only.
are as follows:
• 60554F - Dual Air and Lanyard Operated
• 60554D - Lanyard Operated Pilot Valve for Pilot Valve for deadman control and manual
manual on/off control. Valve allows flow in on/off control for use in small pit (12 or 13”
the fueling direction only. dia.) only. Uni-directional only unless
combined with option J.

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 SM60554 January 2011

• 60554J - Air Operated Pilot Valve for A395 (Special Order only). The Upper and
deadman control with defuel control to allow Lower Valve Assemblies are fastened
flow of fuel in either fueling or defueling together with 15 metric threaded screws
direction. instead of the normal 8 UNF threaded
screws. (Replaced 60554-2D).
• 60554U – Dual Air and Lanyard Operated
Pilot Valve for deadman control and manual • 60554X – Air or fuel operated valve with the
on/off control for use in standard pits (18” or operating portion of the pilot valve contained
larger). Uni-directional only unless combined on a mating unit located on the hose from the
with option J. hydrant servicer.

• 60554-3D - Same as 60554D except material

of outer housing is ductile iron per ASTM

TABLE OF OPTIONS

The following option letters may be combined with the above basic units to customize the valve to fit specific installation
requirements:

OPTION
LETTER DESCRIPTION
A Adds 10-mesh screen between upper & lower halves of unit (81557-10)
B Adds 20-mesh screen between upper & lower halves of unit (81557-20)
C Adds six-position product selection (44290)
D Adds manually operated pilot valve
E Adds air operated pilot valve
F Adds dual air/lanyard operated pilot valve for 12” and 13” pit boxes
G* Adds spool piece to convert inlet flange to mate with 6" 300-lb ASA Raised Face Flange. This option
is required to meet the IP Standard (44364). Resultant height of valve is 18”. (Special Order on
60554-2D & 3D)
H** Adds 4-mesh stone guard to inlet. Available only with "G" option above (43587)
J Adds pilot assembly (de-fuel), air operated, and lower half (de-fuel) valve assembly
K Adds Iinlet adapter kit to basic unit to fit into Avery Hardoll 12" pit. (Some modification to the Avery Hardoll
mounting flange might be necessary). Can not be used with Options G, H or L (44744)
L Adds inlet adapter kit to basic unit to fit into Avery Hardoll 13" pit. (Some modification to the Avery
Hardoll mounting flange might be necessary). Can not be used with Options G, H or K (44745)
M Adds quick disconnect air connection to pilot port. Available only with E, F or J basic units only (44731)
N Adds adapter kit for installing unit into 12 or 13” Avery Hardol Pits with 3” ANSI mounting flanges. Can
not be used with Options G, H, K or L (47077)
P Adds 4” spool piece to convert inlet flange to mate with 6" 300-lb ASA raised face flange (47199).
Resultant valve height is 16.0”. (Special order on 60554-2D & 3D)
Q Replaces standard 2-piece (aluminum/stainless steel) upper with one piece ductile iron upper half
(same as units previous to 2-piece units)(43214)
R Replaces standard 2-piece (aluminum/stainless steel) upper with ductile/stainless steel 2-piece upper
half (47203-2)
S Changes upper half housing to stainless steel (43214-4)
T Adds fusible plug to air pilot line. (47326) (Not available with Option “X”)
U Adds dual air/lanyard pilot valve
X Adds remote pilot connector fitting
Z Adds actuator assembly with override
*This option may have been originally made under license by various Eaton Carter brand distributors and for that
reason may not be exactly the same, although physically and functionally interchangeable.

** This option is not licensed to be made by any company except Eaton and any furnished should be
original equipment. Failure during the extreme high flow testing by API resulted with product made by a
company other than the factory.

Example: 60554BDGH - 18” high IP Standard Unit with 6" inlet, manually operated pilot valve, stone guard
& optional 20-mesh screen.

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 SM60554 January 2011

4.0 SAFETY INSTRUCTIONS/PREVENTATIVE MAINTENANCE

4.1 SERVICING VALVE UTILIZATION - The unit does not appear to be under pressure proceed
incorporates a servicing control valve with the next step.
designed to allow the Upper Housing
Assembly and/or the Pilot Valve to be • Remove the Screws (2-3 & 2-5) attaching
removed while the inlet of the unit is under the Upper Half Assembly (2-6) and Lower Half
pressure. See caution below. Assembly (5-1).

The Lower Housing Assembly consists of a

pressure overbalanced piston assembly that CAUTION!
shuts off the main flow path. The slipper type
As long as the hydrant system pressure is on
seals utilized on the piston are not absolutely
do not attempt to remove the Lower Housing
zero leak seals and an increase in leakage
Assembly (5-1) from the inlet pipe or loosen
past these seals is anticipated with age. If the
the Servicing Valve (4-3).
leakage increases too much, the piston will no
longer stay closed. It is therefore recommended
that the hydrant not be maintained by use of the 4.2 HOT HYDRANT - Refer to paragraph 7.1.2 for
servicing valve on a regular basis and when it is the testing procedure to determine whether a
used, the following procedure should be followed hydrant is “hot” or not. This preventative
to reduce the possibility of a major spillage of maintenance procedure should be conducted
fuel: after one year of service and every six months
thereafter for maximum benefit.
CAUTION!
4.3 OUTLET SAFETY INSPECTION - The 60554 is
It is not recommended that this procedure be designed to meet the break a-way requirements
utilized, except in an emergency condition. of the 3rd Edition of API 1584. To assure that the
The use of this valve does pose a possible unit will continue to meet these requirements it is
hazard if not correctly accomplished and the necessary to annually inspect the outlet
valve is not in good working order. configuration to assure that it meets the
dimensions that allows it to be within
specification.
If an inlet butterfly valve is available, close it to
reduce the inlet pressure from the hydrant
system. WEAR GAUGE NOW AVAILABLE!
• Close the Servicing Valve (4-3) securely, by
hand. The seal on this valve could be damaged A new gauge to check the wear on the outlet
if a wrench is utilized. No threads on the Stem connection of the 60554 is now available as
(4-3) should be visible when the valve is fully part number 60554ST1. It is a “no-go” gauge
seated. in that it checks the two critical surfaces of the
API interface for non-conformance to API 1584
• Manually depress the pressure Equalization and safe usage with any Carter coupler.
Poppet (2-13) and allow the pressure inside the
Upper Housing Assembly (2-6) to bleed. If the
flow from the Equalization Poppet (2-13) The gauge is shown in Figure A below.
reduces to a matter of leakage as differentiated
from continuous flow under pressure, it is safe to
proceed.

CAUTION!
If the flow from the Equalization Poppet (2-13)
is steady and under pressure, do not continue Figure A – 60554ST1 Wear Gauge
to remove the Upper Housing Assembly (2-6).
The gauge has two sides, “A” to check the outer
diameter and “B” to check the angular underside
• On all but Option “X” - Remove the Pilot
wear surface of the outlet configuration. This
Valve (1-D, 1-E, 1-F, 1-J or 1-U) and wait for at
gauge is meant to determine whether the outlet
least one minute while checking the leakage out
will continue to meet the break a-way
of the hole from which the Pilot Valve (1-D, 1-E,
1-F, 1-J or 1-U) or the quick disconnect was requirements of API 1584 if the mating coupler
mounted. If the leakage does not appear to be is a Carter unit and it is also within the wear
under pressure proceed with the next step. tolerance of it wear gauge 61362. See the
appropriate Coupler manual for instructions on
• On Option “X” – Use a ¼” diameter plastic how to use the 61362.
rod to depress the valve stem located within the
quick disconnect fitting and wait for at least one First attempt to pass side “A” across the hydrant
minute while checking for leakage. If the leakage outlet in at least 4 places approximately 45°

5
 SM60554 January 2011

apart. If the gauge can be passed across the 45° apart. If the gauge can successfully be
outlet the outlet is worn and needs replacing. passed across the outlet the gripping surface is
worn and the outlet needs replacing.
Second, attempt to pass side “B” across the
hydrant outlet in at least 4 places approximately

5.0 OPERATION

Figure A reflects a lanyard

operated pilot valve shown in
the open position. The
operation of the Hydrant Valve,
whether the pilot is lanyard, air
operated or new Option “X” is
identical.

Figure A

Figure B reflects the same

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

Figure B

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 SM60554 January 2011

Servicing Valve Closed Pilot Valve Closed

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

6.0 DISASSEMBLY

This disassembly procedure assumes that 6.1 Place the unit in a container sufficiently large
the valve is located within a shop area where enough to contain a minimum of 5 gallons (19
there is the capability of supplying the l) of fuel. Remove the Cover Assy (2-23).
necessary tools. It is also assumed that Push the Adapter Poppet (2-11) open and hold
options G, P or H are not removed from the it open with a flexible plastic rod, or another
pit for maintenance, although the Gasket (1- non-marring item, to allow the unit to drain.
11) used between the two parts (Valve and Hint: A scrap 23620 Rod used in Carter
Spool) should be replaced at each removal 60427 Nozzle is suitable for this job.
of the unit from the pit. The same goes for
spool pieces used as Options K and L (1-K & 6.2 Remove the Servicing Valve (4-3) and set
1-L). aside.

6.3 Turn the unit over onto its outlet, being sure to
Note: place it on a surface that will not damage the
The valve will be full of fuel and provisions for outlet surfaces. Grasp the inlet flange and
draining into a safe container should be made apply pressure to the Piston (4-18) to push it
prior to beginning to work on the unit. open sufficiently to insert a flexible plastic rod
to keep the piston open as with the Adapter
Poppet (2-11) above. Turn the valve over a

7
 SM60554 January 2011

few times to allow the trapped fuel to drain. Poppet Retainer (2-19) to remove it, Spring (2-
The rod can then be removed to close the 18) and Poppet Assy (2-8).
Piston (4-18).
6.8.2 Newer valves may have a “2-piece” upper
6.4 Pilot Valve/Pilot Valve Connector Removal housing. This is easily determined by the
aluminum (no epoxy coating) cast upper
6.4.1 Pilot Valve - Remove Screws (5-29, 6-18, 7-18 housing and the stainless steel adapter ring. If
or 8-18) and Washers (5-28, 6-19, 7-19 or 8- the upper housing is epoxy coated or all
19). Grasp the Pilot Valve (1-D, 1-E, 1-F, 1-J or stainless steel no further disassembly is
1-U) and twist back and forth while applying a possible. If it is the 2-piece upper it is not
force away from the unit to remove the pilot. necessary to disassemble the part farther
While removing the Pilot Valve (1-D, 1-E, 1-F, unless there is a leak at the joint between the
1-J or 1-U) be sure to maintain a straight Ring (3-4) and the Housing (3-2), then the O-
upward pressure to prevent causing a binding ring (3-3) must be replaced. Another reason for
of the parts contained within the Lower further dis-assembly would be to replace the
Housing Assy (4-10). Some of these parts could Ring (3-4) due to severe denting which can
be damaged if a binding during disassembly cause leakage when the coupler is attached.
occurs. Lay the Pilot Valve (1-D, 1-E, 1-F, 1-J
or 1-U) aside for now.
NOTE:
6.4.2 Pilot Valve Connector Assembly (Option “X”) –
Remove the two Screws (9-5) and Washers (9- If the O-ring (3-3) is being replaced it will be
6) to remove Connector (9-2). Remove and necessary to heat the assembly to 300°F (150°
discard O-rings (9-3) and (9-4). If it is C) for at least one-half hour before trying to
necessary to remove the Valve Stem remove the Screws (3-5). Trying to remove
Assembly (9-7) special tool T221790 will be them at room temperature may result in
needed to unscrew it from the lower housing. If twisting them off due to the use of Locktite to
removed discard O-ring (9-8). If removed the retain them in place. If the Ring (3-4) is being
Stem (9-11) may be replaced by first placing a replaced then damaging the screws is of no
small bladed screwdriver into the hole in the concern since the ring will be discarded along
Spring Guide (9-9) and pry the spring guide with the screws.
from the part. This allows one to remove the
other parts within and to replace the stem if
Then remove the Screws (3-5) and Washers
necessary.
(3-6) from the inside of the unit. Carefully pry
the stainless steel Ring (3-4) from the Housing
6.5 Remove Screws (2-3 & 2-5) and Washers (2-
(3-2). Remove and discard O-ring (3-3).
4). Note that Screw (2-5) is shorter than
Screws (2-3). It should be noted that it was 6.8.3 Using a thin blade screwdriver, carefully pry an
installed in the hole to the left of the Pilot Valve end of the Retaining Ring (2-17) and remove it
(1-D, 1-E, 1-F, 1-J or 1-U) when facing the unit from its groove. Disassemble Poppet Assy (2-8)
with the Pilot Valve (1-D, 1-E, 1-F, 1-J or 1-U) removing the various parts. Remove Seal Ring
directly in the center. Note that on newer units (2-9) from Seal (2-10) and discard Seal (2-10).
this shorter Screw (2-5) is made of stainless Remove and discard Seal (2-12).
steel, for ease of identification only, instead of
the normal cadmium plated Screws (2-3). 6.8.4 If present and the valve is the obsolete style
that utilized bosses cast onto the Upper
6.6 Using a thin, wide blade screwdriver, gently pry Housing (2-7), there is no need to disassemble
the Upper Half Assy (2-6) from the Lower Half the product selection part of the Upper Half
Assy (4-1). Be careful not to damage the Assy (2-6) unless parts need replacing due to
epoxy coating. Remove and discard O-ring (2- missing or damaged parts. On newer valves,
22). Set the Lower Half Assy (4-1) aside. these bosses were removed and the product
selection feature is achieved by the addition of
6.7 Remove Strainer (2-21), if present, from unit. the Product Selection Ring Assy (1-C). This
Set it aside. ring is attached to the unit by using four extra
long Bolts (1-5) and Standoffs (1-2). It is then
6.8 Upper Half Assy (2-6) - Remove the plastic rod necessary to disassemble the Product
holding the Poppet (2-11) open and install the Selection Assy (1-C) from the unit during
Cover Assy (2-23) to protect the Upper Half disassembly of the valve. On older versions of
Assy (2-6). Turn the unit over onto the Cover the newer valves, the Ring (1-1) holding the
Assy (2-23). product selection studs is a solid one piece
ring. On newer valves the ring is composed of
6.8.1 While pushing downward on Poppet Retainer four equally thick stamped Rings (1-1). The
(2-19), using a thin blade screwdriver, remove older units utilize one piece product selection
Retainer Ring (2-20) from Upper Housing (2- studs while the newer units utilize standard
7). Slowly release downward pressure on Bolts (1-3) and a stack of Washers (1-4 & 1-6).
If replacement of either the older ring or the

8
 SM60554 January 2011

studs is required, utilize the newer 6.10 Operated Pilot Valve (1-E) - In the history of
replacement parts. the 60554 Hydrant Valve there have been
three different Pilot Valves utilized:
6.9 Lower Half Assy - Turn Lower Half Assy (4-1)
over to expose the inlet flange. Remove • Current (1991 & later) production unit, part
Screws (4-15). Early versions of the unit number 44721, utilizes the same Housing (6-1)
utilized only two Screws (4-15) to retain the and Piston (6-14) as is used on the Defueling
Piston Retainer (4-16). The later versions Pilot Valve (1-J). A Spacer (6-17) is added on
utilize six. This change was made necessary the Shaft (6-16) between the Housing (6-1)
on a similar valve, model 61654 with a six inch and the Piston (6-14). The change to this unit
ANSI flange. On the model 60554, the Piston was made to standardize on production parts
Retainer (4-16) is retained in place by the between the pilot valves used on both Options
mating pipe flange hence the mandatory use of E and J. The only way to tell the obsolete pilot
six screws is not necessary. However, if there valve apart from the current production unit is
are six present, all six should be replaced. to disassemble the unit and check for the
Note: If Screws (4-15) are difficult to remove, presence of the Spacer (6-17) or to look at the
an impact wrench may be necessary to bottom of the Piston (6-14) chamber of the
prevent damage to the Phillips recesses of the Housing (6-1). If the chamber bottom is flat
Screws (4-15). Also note: Normally, the main bottomed as opposed to a conical bottomed,
Spring (4-26) will be strong enough to force the the pilot valve is of current design. If the
Piston Retainer (4-16) out of the unit. If not, bottom is conical, the pilot valve is an old style
use a thin blade screwdriver to carefully pry 44247.
out Piston Retainer (4-16). Remove and
discard O-Ring (4-17). • On newer valves (after first quarter 2000)
the Housing (6-1) may be changed to provide
6.9.1 Remove Piston Assy (4-18 to 4-21), Spring (4- better production economics. The newer
26), Washer (4-27) and Seal (4-28). Discard valves may use the housing from the dual
Seal (4-28). Remove Screws (4-19), Seal air/lanyard operated pilot valves with a Plug (6-
Retainer (4-20) and Seal (4-21). Discard Seal 27) to fill in the extra air port. This also gives
(4-21). Using an o-ring pick, carefully remove the option to install the air connection in either
and discard O-Ring (4-22) and Slipper Seal (4- of the available ports to move the connection
23) from Piston (4-18). farther away from possible damage from the
dropping of the coupler onto the valve.
6.9.2 Using an o-ring pick, carefully remove Piston
Seal (4-25) and O-Ring (4-24) and discard • Previous generation Pilot Valve (1-E) - As
both. mentioned above, this unit has a conical
bottomed piston chamber. The Piston (6-14) is
6.9.3 Check to see if the Shaft (4-12) is loose in the also different. The older Piston (6-14) will not
Lower Housing (4-11) only, do not attempt to work in the newer pilot valve. Should an older
remove Screw (4-14), Washer (4-13) or Shaft Housing (6-1) be needed for replacement, it will
(4-12) from Lower Housing (4-11). The Shaft be necessary to also procure a new Piston (6-
(4-12) is press fitted into the Lower Housing (4- 14), Spacer (6-17) and the new Housing (6-1).
11) and neither part is available as a
replaceable spare part. If it is necessary to • First generation Pilot Valve (1-E) - This
replace the Shaft (4-12), it is necessary to Pilot Valve, part number 42846, utilized some
replace the Housing Assy (4-10) as a complete of the same parts as are currently utilized.
unit. However, there are major differences. One of
these differences can be upgraded to current
6.9.4 Using an appropriately sized wide blade production by utilizing kit 2KD42836, provided
screwdriver, remove the Cage (5-18, 6-2, 7-2 the existing Cage (6-2) is still usable. This kit
or 8-2) from Lower Housing (4-11) by replaces the fixed pilot seal poppet with a
unscrewing counter clockwise. Remove and "floating" design for more reliable operation.
discard O-Ring (5-1, 6-11, 7-11 or 8-11) from Since the older parts have been out of
Cage (5-18, 6-2, 7-2 or 8-2). production for many years, it may be
necessary to consider replacing the entire Pilot
6.9.5 It is not necessary to remove the Orifice (4-29)
Valve 42846 with Pilot Valve 44721.
located in one of the internal holes visible
through the Servicing Valve (4-3) port. Using It is not necessary to remove the Air Quick
shop air pressure, blow air through the Disconnect or Fusible Plug (1-M or 1-T if
opening to clear the Orifice (4-29). If the air furnished as such) from the unit unless it is
does not flow easily through the orifice out necessary to replace the unit.
through the inner part of the Lower Housing (4-
11), the Orifice (4-29) may be plugged. In that Compress Spring (6-7) with Spring Retainer
case, it will be necessary to remove the Orifice (6-6) sufficiently to remove Pin (6-4). This
(4-29) and either clean it or replace it. allows the removal of Poppet (6-3). Slide
Spring (6-7) off of Shaft (6-16). Unscrew
Adapter (6-5) from Shaft (6-16). Slide O-Ring

9
 SM60554 January 2011

Retainer (6-8) off of Shaft (6-16). Carefully pick Cable Clamp (5-15) utilized is crimped onto the
out O-Ring (6-9) from Housing (6-1) and Cable (5-10).
discard. Remove and discard O-Ring (6-10).
Remove Cover (6-12) and Spring (6-13). Push • The first generation Lanyard Operated
Piston (6-14) out of Housing (6-1). Remove Pilot Valve, 42836, has the fixed pilot poppet
Spacer (6-17). It is not necessary to unscrew design and utilizes a two piece screwed together
Shaft (6-16) from Piston (6-14) unless either Cable Clamp (5-15A). The pilot poppet seal is
part is damaged and must be replaced. Remove replaceable and is held in place by a screw.
and discard Bal Seal (6-15) from Piston (6-14).
Compress Spring (5-24) with Spring Retainer
6.11 Air Operated Pilot (1-E), 44247 (Obsolete) - (5-23) sufficiently to remove Pin (5-20). This
Follow above procedure in paragraph 6.10 allows the removal of Poppet (5-22). Slide
except the following parts are different: Spring (5-24) off of Shaft (5-16). Unscrew
Adapter (5-21) from Shaft (5-16). Slide O-Ring
Housing (Obsolete) instead of Housing (6-1) Retainer (5-25) off of Shaft (5-16). Remove
Pilot Retainer (5-27) and carefully pick out O-
Piston (Obsolete) instead of Piston (6-14). Ring (5-26) and discard. Remove and discard
O-Ring (5-19).
6.12 Air Operated Pilot (Defueling type) (1-J) -
Newer valves (those received after the first Push Latch Spool (5-4) to force the Shaft (5-
quarter of 2000) may have a different defuel 16) out of Housing (5-2) sufficiently to remove
control screw. The Screw (6-23) was Pin (5-17). If the pilot latching mechanism
shortened and made with a larger thread size requires servicing, cut the Cable Assy (5-10) or
to help prevent operators from bending it when Clamp (5-15) after removing Hose (5-13) and
the coupler is dropped onto the hydrant. This Clamp (5-14). Cable Assy (5-10) can then be
made it necessary also to change the Cover pulled back through Latch Bracket (5-9) to
(6-22) and Pin (6-24) to suit. Ordering any of allow removal of Spring (5-12) and Latch Stop
the older parts will automatically be entered as (5-11). If the Latch Bracket (5-9) is to be
the pre-assembled Screw Assembly (6-21). In replaced, mount Housing (5-2) in a suitably
addition the Housing (6-1) was changed to padded vise and pull Pins (5-8) with pliers.
provide better production economics. The
newer valves may use the housing from the If necessary to replace parts, using a .187
dual air/lanyard operated pilot valves with a (4.750 mm) dia. drift pin, remove Pin (5-7)
Plug (6-27) to fill in the extra air port. This also from Handle (5-6) and Latch Spool (5-4). Note
gives the option to install the air connection in on older valves the hole in the Handle (5-6) for
either of the available ports to move the this Pin (5-7) is on center. Newer valves have
connection farther away from possible damage the hole to one side. Even newer valves have
from the dropping of the coupler onto the a ball attached to the Handle (5-6) to prevent
valve. possible interference between the Handle (5-6)
and the mating coupler bumper. Do not try to
The disassembly procedure is the same as in remove the ball from the end of the Handle (5-
paragraph 6.10 except for the following 6) unless it is loose and needs replacing.
changes and the addition of several parts as
noted: 6.14 Air/Lanyard Operated Pilot (1-F) - It is not
necessary to remove the Air Quick Disconnect
Cover Assy (6-21) instead of (6-12). (1-M if furnished as such) or the Fusible Link
(1-T) from the unit unless it is necessary to
Additional parts include Defuel Control Screw
replace the unit.
(6-23), Pin (6-24), Wave Washers (6-25),
Washers (6-26) between the Wave Washers Compress Spring (7-7) with Spring Retainer (7-6)
(6-25) and Wear Plate (6-20) between the sufficiently to remove Pin (7-4). This allows the
Piston (6-14) and the screw on the Cover (6- removal of Poppet (7-3). Slide Spring (7-7) off of
22). Cover (6-22) need not be disassembled Shaft (7-16). Unscrew Adapter (7-5) from Shaft (7-
unless some part is damaged and needs 16). Slide O-Ring Retainer (7-8) off of Shaft (7-
replacing. 16). Carefully pick out O-Ring (7-9) from Housing
(7-1) and discard. Remove and discard O-Ring (7-
6.13 Lanyard Operated Pilot (1-D) - In the history of
10). Remove Cover (7-12) and Spring (7-13).
the 60554D Lanyard Operated Valve, there have
Push Piston (7-14) out of Housing (7-1). Remove
been two different Lanyard Operated Pilots,
Spacer (7-17). It is not necessary to unscrew Shaft
42836 and 44248. These units can be identified
(7-16) from Piston (7-14) unless either part is
as follows:
damaged and must be replaced. Remove and
• The current design unit incorporates a discard Bal Seal (7-15) from Piston (7-14).
floating pilot poppet design to provide for more
Remove Valve Assembly (7-20) from
reliable operation. The Poppet (5-22) has a
Housing (7-1) to repair parts within Valve
bonded on rubber seal. The Cage (5-18) now
Assembly (7-20). Using a drift pin remove
used is interchangeable with the older cage. In
Pins (7-21) being sure to adequately support
addition, when the valves leave the factory, the

10
 SM60554 January 2011

the Valve Assembly (7-20) so as not to Spacer (8-17). It is not necessary to unscrew
damage it. Disassemble Connector (7-22) Shaft (8-16) from Piston (8-14) unless either part
from Seat (7-23). Items (7-24) through (7-28) is damaged and must be replaced. Remove and
may be removed for replacement as discard Bal Seal (8-15) from Piston (8-14).
required. Unscrew Guide (7-29) from
Connector (7-22). Items (7-30) through (7- Remove Air Bleed Valve Assembly (8-21) by
33) may be removed for repair or removing the three Screws (8-20) and pulling
replacement. Do not remove Ring (7-35) Valve Assembly (8-21) from Housing (8-1).
unless replacement of the Reset Ring (7-36) Using a drift pin remove Pin (8-22) being sure
or Guide (7-29) is necessary. Do not remove to adequately support the Valve Assembly (8-
Cable Assembly (7-37) unless it is necessary 21) so as not to damage it. This frees up
to repair or replace it. If necessary, cut several parts attached by means of the Pin (8-
Cable (7-40) after removal of Clamp (7-39) 22). Remove Pin (8-26) as above. Unscrew
and Hose (7-41) to repair. Cable Retainer (7- Guide (8-30) from Connector (8-23). Items (8-
33) can also be removed from the cut cable 31) through (8-34) may be removed for repair
assembly. or replacement. Do not remove Ring (8-36)
unless replacement of the Reset Ring (8-37) or
6.15 Air/Lanyard Operated Pilot (1-U) - It is not Guide (8-30) is necessary. Do not remove
necessary to remove the Air Quick Disconnect Cable Assembly (8-38) unless it is necessary
(1-M if furnished as such) or the Fusible Link to repair or replace it. If necessary, cut Cable
(1-T) from the unit unless it is necessary to (8-41) after removal of Clamp (8-40) and Hose
replace the unit. (8-42) to repair. Cable Retainer (8-34) can also
Compress Spring (8-7) with Spring Retainer be removed from the cut cable assembly.
(8-6) sufficiently to remove Pin (8-4). This 6.16 Servicing Valve (4-3) - Carefully using a .156
allows the removal of Poppet (8-3). Slide inch (3.960 mm) drift pin, remove Pin (4-7).
Spring (8-7) off of Shaft (8-16). Unscrew Remove Stem (4-6) from Poppet Retainer (4-
Adapter (8-5) from Shaft (8-16). Slide O-Ring 8). Remove and discard O-Ring (4-9) and
Retainer (8-8) off of Shaft (8-16). Carefully Gasket (4-2). If Poppet (4-4) does not need
pick out O-Ring (8-9) from Housing (8-1) and replacement, do not disassemble further. If
discard. Remove and discard O-Ring (8-10). necessary, using snap ring pliers, remove Ring
Remove Cover (8-12) and Spring (8-13). Push (4-5) to replace Poppet (4-4).
Piston (8-14) out of Housing (8-1). Remove

7.0 INSPECTION

7.1 PERIODIC INSPECTIONS air system can occur at any of the air-fuel
interface points. These are normally found in
The inspections listed in this section should be either the line mounted pressure control valves,
conducted on a periodic basis, the frequency of hydrant couplers, float operated water sump
which should be no less than that mentioned in control valves or at the hydrant valve. Some of
each section. The time between testing should be these types of components, Carter 60700-1
tailored to fit the particular operation and age of the Hydrant Coupler and 61024 Line Mounted
system. Pressure Control Valve, can be eliminated from
consideration since they have a vent between the
7.1.1 Fuel-in-the-air Check (applicable to all Options
air to fuel interface. If the fuel seal leaks on these
but D and X) - It is recommended that this
units, it results in an external leakage out of the
inspection procedure be conducted initially on
vent point, not into the air system.
new units after one year of operating and then
each six months thereafter. 60554E, 60554J, 60554F and 60554U Hydrant
Valves utilize air operated pilot valves with an air-
Air operated hydrant valves are one possible
to-fuel interface seal that is not vented, hence are
source of contamination when fuel leaks into the
candidates for fuel to the air system leakage with
air systems. (If Option “X” is being used and there
time.
is fuel leaking into the air system, the culprit may
be in the 64230 or 64231 Pilot located on the Finding fuel in the air pilot's air chamber is not
hydrant servicer hose). Many of the standard air conclusive that the air pilot is the leakage
components used within a refueling system are source. However, every air pilot that is leaking
not necessarily fuel resistant, hence the results will have the symptom of fuel in its operating air
can be costly and time consuming. In addition, cavity and quick disconnect fitting (if so fitted).
fuel contamination in the air system will quickly be
apparent by the expelling of a fuel mist out of the The most obvious evidence that the air pilot is
exhaust of the deadman valve. This is not a safe responsible for air system contamination is
situation around hot jet engines. Air operated steady flow (or weapage) of fuel emitting from
hydrant valves are not the primary source of the the quick disconnect fitting that is mounted to the
problem, just a possibility. Leakage of fuel into the air pilot. This confirmation will be made possible

11
 SM60554 January 2011

only if the fitting is specifically designed to allow  Servicing Valve - A mechanical valve
air to bleed from within the air pilot's air cavity. If located in series with the Pilot Valve (between
the quick disconnect fitting is full of fuel, but the Inlet Shutoff Valve and the Pilot Valve). It is
leakage flow, as described above, is not designed to keep the Inlet Shutoff Valve in the
obvious, then the following procedure can be closed position while allowing the changing of
used to confirm that the air pilot is responsible the upper half of the valve (Outlet Adapter)
for the leakage. including the Pilot Valve.
Remove the quick disconnect fitting and dry the Within the above sections of the hydrant valve
interior of the air cavity and fitting with a blast of there are various seals that prevent leakage
clean, dry air. Perfection in this is not required, between the elements. In a valve that is in good
but closely examine and mentally record the mechanical condition, the Inlet Shutoff Valve and
condition of the air cavity after cleaning for Pilot Valve combine to keep the chamber
comparison as noted below. between the Inlet Shutoff Valve and the Outlet
Adapter at a lower than inlet pressure. This is
Refit the quick disconnect fitting. Establish full only possible, theoretically, if there is zero
hydrant system pressure to the hydrant's inlet. leakage past the piston and Pilot Valve seals.
Using a clean, dry source of air, which is set to Any leakage, with the passage of time, will allow
the same pressure used during normal operation this chamber to increase to inlet pressure. Fuel is
of the air pilot, apply and then remove the air not compressible, hence a very small amount of
pressure, cyclically, thirty (30) times (one to two leakage will raise the pressure in this chamber to
seconds on, then one to two seconds off). When inlet. This does not mean that a hydrant valve is
completed, remove the air fitting and inspect the always "hot". If the leakage rate past the
air cavity again. Any accumulation of fuel, not appropriate seals is greater than the amount of
logically associated with residual moisture flow possible through the pressure equalization
available in the air cavity, indicates that the air valve (at the time the coupler is attached and
pilot is responsible for air system contamination. begins to be opened) then the valve is "hot". In
Replace this air pilot with a new or rebuilt air other words, the equalization valve's capacity is
pilot. Overhaul of the air pilot while in the pit is insufficient to reduce the pressure in this
not recommended. chamber during the coupler opening operation.
If no significant fuel is found in the air chamber WHAT PROBLEMS ARE CAUSED BY HOT
after the above investigation, it can be assumed HYDRANTS? - Two major problems, not readily
that the residual fuel previously seen in the air apparent, are caused or are potentially caused
chamber came from another source (coupler or by hot hydrants.
in line valve).
• Hot hydrant valves make the opening of
7.1.2 "Hot Hydrant" Check - A Carter hydrant valve the hydrant coupler more difficult. The hydrant
consists of four major components all contained valve has a poppet area, against which pressure
within a single valve element: reacts, of approximately 12.6 square inches. If
the pressure against which this poppet must be
• Outlet Adapter - A spring loaded poppet
opened is reduced appropriately by the pressure
valve that is manually opened and allowed to
equalization valve to about 20 psi, the opening
close by the opening and closing of a mating
force that must be generated by the coupler
coupler. A pressure equalization valve is
mechanism is only 252 pounds. If, on the other
contained within the poppet. This allows the
hand, the valve is hot and the inlet pressure is
trapped pressure in the upper chamber of the
as much as 150 psi, the opening force must be
valve to be bled into the hydrant coupler when
1,890 pounds. Under normal pressure
extending the poppet to the open position.
conditions, it is relatively easy to open a valve
 Inlet Shutoff Valve (Isolation Valve in the against 20 psi with the application of
terms of the IP) - A spring loaded piston valve approximately 30 pounds force applied to the
whose chamber is connected to the inlet of the coupler handle (mechanical advantage reduces
hydrant valve via an orifice and to the outlet the force required). If the pressure is increased,
through the servicing and pilot valves. Its function by a hot hydrant, to 150 psi, the force
is to control opening and closing times and to necessarily applied to the coupler handle is
present a means for shutting off flow at the end of increased to 225 pounds. This is outside of the
a refueling operation, either by means of a lanyard realm of an average refueler so he will use his
or air operated pilot valve. foot and force the handle to the open position.
This tends to over stress the coupler mechanism
 Pilot Valve or the Valve Connector resulting in a premature failure condition, hence
Assembly (on Option “X”) - Either the Valve expensive, unnecessary maintenance costs.
Stem Assembly on Option “X” or a lanyard or air
operated valve that controls the outlet bleed path  A hot hydrant valve, caused by a failed Pilot
from the Inlet Shutoff Valve to the chamber (including the Valve Stem Assembly (9-7) on
between the Inlet Shutoff Valve and the Outlet Option “X”) or Inlet Shutoff Valve can be a
Adapter. potential major spill, with the possibility of a fire. A
recent incident, with a competitor’s hydrant valve,
12
 SM60554 January 2011

resulted in a major spill. The coupler was knocked in the first test (assuming that the leakage was
off a functioning hydrant valve by a baggage cart. well below the 500 cc/min. allowable), it is a good
The Outlet Adapter Poppet stuck open and the indication that the pilot valve seals or valve stem
Inlet Shutoff Valve failed to close because of a are leaking and in need of overhaul. If the leakage
non-functioning air operated pilot, even though the rate is significantly lower, the first assumption that
air hose to the unit was also severed. The result the majority of the leakage originally measured
was a fairly major spill and luckily no fire. The was through the piston seals was faulty and it
failure was caused by the fact that the Pilot could be an indication that the seals of the
Valve's poppet, a synthetic ball, had deteriorated servicing valve are faulty. If the leakage rate
resulting in the failure. Subsequent testing of other remains approximately the same as in the first
valves at the location revealed nearly 50% were in test, the pilot valve and servicing valve seals
the same dangerously potential situation. Periodic would appear to be performing well and that the
testing of the hydrant valves would have original assumption (leakage past the piston) was
prevented this situation from occurring. The fixing correct.
of the hot hydrant valves would also make the
refueling operation easier and reduce, significantly,  Disconnect the test coupler and close the
the coupler maintenance costs. pilot valve (leave the 64230/ 64231 Actuator
disconnected on Option “X”) before completing
TESTING PROCEDURES - It is recommended the test.
that all new hydrant valves be tested after one
year of service and at lease twice each year  Simple Test (will not test Servicing Valve
thereafter and any indicated hot hydrant valves Seals) - This test can be conducted on air
be removed for maintenance immediately. The operated units with the same equipment less the
test procedure recommended is the same for a pressure source but it is not as complete and will
lanyard or air operated unit. not test the Servicing Valve. The Pilot Valve will
remain closed during all phases of this test.
 Equipment Required - 61525E Coupler with
pressure sense port in the elbow and the outlet  Close the Servicing Valve and conduct the
plugged or a standard 61525 (any outlet thread) leakage test specified above.
with a small (3/8") port in the outlet plug. A 60 psi
air or nitrogen pressure source (for air operated  Open the Servicing Valve and recheck the
valves only); a short length of 3/8" plastic tubing or leakage. If the leakage increases significantly, the
hose attached to the pressure sense or outlet port, pilot valve seals or valve stem assembly on Option
a manual valve in the hose or tube; a 1000 cc “X” will be the contributor to the increased leakage.
beaker; and a plastic 2 gallon bucket. (Note if a If the total leakage is less than 500 cc/minute, the
metal bucket is used, check with your company valve can continue to be used. If greater, replace it
manual about electrical bonding of the bucket to immediately.
the coupler before proceeding.)
7.2 DETAIL PARTS INSPECTION
 Inlet Piston Valve Seals Test - Attach the
It is recommended that the parts in the following
above test coupler to the test hydrant valve with
table be replaced at each overhaul. Detail
the coupler of the small shutoff valve open to the
inspection of parts shall be conducted in
bucket and open the hydrant valve by pulling the
accordance with the information in the following
“T” handle of Option D or by applying 60 psi air
paragraphs.
pressure to the pilot port of Options E or J. Allow
the hydrant valve and coupler to be bled of air.
Close the servicing valve of the test hydrant. Allow SAFETY NOTE:
the leakage, if any, from the outlet to stabilize for
about 30 seconds, then measure the leakage for at Any and all quick disconnect fittings used to
least 30 seconds. The amount of leakage caught connect the air system to the hydrant valve must
in the 30 seconds should not exceed 250 cc. If it be configured or altered to not tightly shut off the
does, the hydrant valve should be tagged for air pilot's air cavity. Without this feature, full
removal and overhaul. hydrant system pressure could build in the air
pilot's air cavity as a result of the leaking air pilot.
 Pilot Valve, Valve Stem Assembly on Option The hydrant would then be in an open condition
“X” & Servicing Valve Seals Test - Close the or would be a "hot" unit causing problems in
pilot valve (pull the lanyard on Option D, remove connecting the coupler. This would defeat the
the air pressure from Options E, F or J) or on safe use of the hydrant as it was designed and
Option “X” do not connect the hydrant hose from would increase maintenance costs for the
the service cart and open the servicing valve. coupler.
(The valve will remain in the closed position and
the leakage rate under this condition should
remain the same as in the test above, assuming
the leakage measured was the result of faulty
piston seals). Repeat the leakage test above. If
the leakage is significantly greater than that noted

13
 SM60554 January 2011

Parts to be replaced at each overhaul:

Item Item
Number Description Number Description
1-32 O-ring 5-19 O-ring
2-10 Seal 5-26 O-ring
2-12 Seal 6-9 O-Ring
2-22 O-Ring 6-10 O-Ring
3-3 O-Ring (only if disassembled) 6-11 O-Ring
4-2 Gasket 6-15 Bal Seal
4-9 O-Ring 7-9 O-ring
4-17 O-Ring 7-10 O-ring
4-21 Seal 7-11 O-ring
4-22 O-Ring 7-15 Seal
4-23 Seal 8-9 O-ring
4-24 O-Ring 8-10 O-ring
4-25 Seal 8-11 O-ring
4-28 Seal 8-15 Seal
5-1 O-ring 8-29 Pin
5-10, 7-40, Cable Assy (if cut during disassembly or
or 8-41 worn only )

7.2.1 Inspect all metal parts for dings, gouges, utilized for sealing purposes can be
abrasions, etc. Use 320 grit paper to smooth and accomplished by using the process outlined in
remove sharp edges. Replace any part with the following paragraphs.
damage exceeding 15% of local wall thickness.
Use alodine 1200 to touch up bared aluminum.  Degrease the entire area to be repaired,
plus approximately one (1) inch (25 mm)
7.2.2 If present, inspect Strainer (2-21) for damage beyond, with a good commercial
and presence of dirt. Clean thoroughly to degreasing solvent.
remove any potential blockage.
 With an abrasive media, emery paper or
7.2.3 Inspect the exterior sealing and interior sealing steel wool, abrade the previously cleaned
surfaces on the outlet of the Upper Half Assy (2- area, to the bare metal if practical.
6), where it mates the hydrant coupler and
where the Seal (2-10) makes contact, for nicks,  With a paint brush, apply one coat of
gouges or other distortions that may be a cause Henco-Phos 1326 Base (E/M
for leakage during operation. If the two-piece Corporation) in accordance with the
upper housing is present and the sealing surface manufacturer’s instructions, and allow to
is damaged, replace Ring (3-4). Check the red air cure, approximately one hour.
coating, if present for chips and missing  Utilizing a mixing dish and utensil, mix the
portions. If the chips are apparent in the various two part epoxy kit, Everlube 13-509 (E/M
sealing areas, it is necessary to strip and recoat Corporation), in accordance with
the part. This can be accomplished by either of instructions provided with the kit.
two companies:
 Within a four hour period, liberally apply
E/M Corporation, 6940 Farmdale Ave., North the mixed Everlube 13-509 coating to the
Hollywood, CA 91605, Telephone (213) 875- prepared surface, with a paint brush in
0101. Their product is Everslik 1201 and is accordance with instructions provided
applied .001 to .005 thick. with the kit. Make certain the entire
prepared surface is coated. Allow to air
Whitford Corporation, Box 2347, West Chester,
cure until completely dry. Keep away from
PA 19380, Telephone, (215) 296-3200, Fax
fuel or other solvents for at least 8 hours.
(215) 647-4849. Their product is Xylan 1014 and
is applied .001 to .005 thick. Whitford 7.2.4 Check the underside of Ring (3-4) or the same
Corporation has facilities or agents in various surface on Upper Housing (2-7) on older units.
countries throughout the world. Contact Carter This is the 45° bevel that contacts the lugs of the
or a Carter distributor for more information about hydrant coupler. This surface should be smooth
a local source. and continuous. If there are worn or flat spots on
this surface, the part should be replaced.
If neither of these products are available, an
equal epoxy coating would be suitable provided 7.2.5 Inspect the Lower Housing (4-11) for damage to
the thickness is controlled to the above limits. the red coating as was done with the Upper
Limited repairs to the surfaces that are not Housing (2-7). Repair such damage in
14
 SM60554 January 2011

accordance with the instructions in paragraph 7.2.9 Inspect the Latch Bracket (5-9) for wear or
7.2.3 above. rounded edge where it contacts the Latch Spool
(5-4). Replace if this corner is rounded more
Check all sealing surfaces for nicks, gouges or than .04 (1 mm).
other damage that might cause leakage.
7.2.10 Check the Latch Spool (5-4) corner that comes
Verify that the Orifice (4-29), located in one of in contact with the Latch Bracket (5-9). If this
the holes visible through the Servicing Valve (4- corner is worn to more than .04 (1 mm) replace
3) port in the Lower Housing (4-11) has not been the Latch Spool (5-4).
removed and not replaced during earlier
overhauls. This orifice controls the opening time 7.2.11 Inspect the lanyard Cable Assy (5-10), (7-37) or
of the unit. (8-41) for wear or fraying. Replace as necessary.

7.2.6 Inspect Poppet (4-4) for damage or to assure 7.2.12 Inspect Cable Retainer (7-33) or (8-34) on
that the rubber portion is still bonded in place. If Air/Lanyard Pilot Valve (1-F) or (1-U) for wear,
there is a permanent indentation in the sealing replace if worn.
surface of the rubber, discard and replace.
7.3 If after using the wear gauge in accordance with
7.2.7 Inspect Poppet (5-22, 6-3, 7-3 or 8-3) as in paragraph 4.3 and the unit fails either the test
paragraph 7.2.6 above. using Side A or B of the wear gauge, run older
units replace the entire Upper Halve (2-7) with
7.2.8 Inspect the sealing surface of the Housing (6-1), the two-piece Upper Half Assembly (3-1) and
(7-1) and (8-1), especially the inside diameter in newer units replace only the Ring (3-4) and its
which the Piston (6-14), (7-14) and (8-14) slides. O-ring (3-3).
Polish out any irregularities that may have been
caused by incursion of dirt or corrosion using a
very fine emery cloth. Replace if the irregularities
can not be polished out completely.

8.0 REASSEMBLY

Reassemble in reverse order of disassembly, (2-9) inside of the groove within the Seal (2-10)
noting the following: and wind it smoothly into the Seal (2-10) being
sure not to have the Seal Ring (2-9) cross over
8.1 Upper Housing Assy (2-6) itself.
8.1.1 If 2-piece Upper Housing Assembly (2-6A) is 8.1.3 Place the Cover (2-23) onto the Upper Housing
present and has been disassembled, place O-ring (2-7) to protect the sealing surfaces and turn the
(3-3) in the groove in Housing (3-2) and install unit onto the covered end. Install the Poppet
Ring (3-4) with Screws (3-5) and Washers (3-6) Assy (2-8) into the Upper Housing Assy (2-7).
using Loctite (3-7). Apply Loctite #603 to Place the Spring (2-18) into the Poppet Assy (2-
threaded holes on Ring (3-4 ) prior to 8) and install the Poppet Retainer (2-19), holding
installation. Note: Screws should be thoroughly it in position while inserting the Retainer Ring (2-
cleaned with acetone prior to using Loctite. 20) into the groove within the Upper Housing (2-
Tighten and torque Screws (3-5) per PS30-101 7). Once the Retainer Ring (2-20) is seated, the
(final torque 25 in-lbs). Allow Loctite to cure for Poppet Retainer (2-19) can be released.
at least eight hours. After curing, verify installtion
process by applying 40 in-lbs torque, 8.1.4 Turn the Upper Housing Assy (2-6) over and
counterclockwise to screw. There shall be no remove the Cover (2-23). Push the Poppet Assy
movement of the screw when torque is applied. (2-8) open and closed several times to assure
that there is no binding and that all parts are
Install Seal, (2-12) into Poppet (2-11) such that properly retained.
the larger diameter bead of rubber is positioned
into the cavity in the Poppet (2-11) and the 8.2 Lower Housing Assy (4-1)
smaller diameter bead of rubber will contact the
equalization Poppet (2-13). Finish assembling 8.2.1 With the Lower Housing Assy (4-1) placed such
the Poppet Assy (2-8), being certain that the that the inlet flange is up (be careful that the unit
Retaining Ring (2-17) is fully seated within the is placed on a smooth clean surface to prevent
groove in the Poppet (2-11). The pressure damage), insert O-Ring (4-24) into the groove in
equalization Poppet (2-13) should protrude the Lower Housing (4-1). Hint: Grasp the O-Ring
beyond the Poppet (2-11) and return to a seated (4-24) in both hands and stretch it approximately
position when depressed by hand and released. 0.5 to 1.0 inch (12 - 25 mm) before inserting into
groove. Place Slipper Seal (4-25) such that the
8.1.2 Place the Seal (2-10) in the groove created by flanged portion of the seal is facing upward (leg
the assembly of the Poppet (2-11) and Shroud of seal into valve), carefully install it into the
(2-16). Using fingers only place the Seal (2-10) groove over the O-Ring (4-24). It will be
into the groove. Place one end of the Seal Ring necessary to deform the Slipper Seal (4-25) into

15
 SM60554 January 2011

a slight "heart" shape to insert it into the bore, this assembly aside for later reassembly into
however, do not exaggerate the deformation and unit.
do not crease the part. Smooth the installed
Slipper Seal (4-25) on its inside diameter with a 8.4 Air Operated Pilot Valve (1-E)
thumb to assure there are no wrinkles. Place a
8.4.1 Carefully install the Seal (6-15) onto the Piston
light coat of seal lubricant (specified earlier in
(6-14) being certain that the open portion of the
this document) onto the Slipper Seal (4-25).
"U" is facing away from the major portion of the
8.2.2 Place O-Ring (4-22) into groove in Piston (4-18). piston (faces in the same direction as the Shaft
Carefully insert Slipper Seal (4-23) into the (6-16)). Lightly lubricate it. If Shaft (6-16) was
groove over the O-Ring (4-22). Smooth Slipper removed it should be reinstalled.
Seal (4-23) with finger to remove all possible
8.4.2 Drop Spacer (6-17) into its groove in the
wrinkles. Place a light coat of seal lubricant
Housing (6-1). (Note: if there is no groove to
(specified earlier in this document) onto the
receive the Spacer (6-17), the unit is not a
Slipper Seal (4-23).
current production unit. Refer to paragraph 6.10
8.2.3 Place Seal (4-21) onto the face of the Piston (4- for information about the identification of air
18) and smooth into place. Place the Seal operated pilot valves.). Carefully install the Bal
Retainer (4-20) onto the Seal (4-21) and Piston Seal (6-15) onto the Piston (6-14) being certain
(4-18) and hold in place while installing Screws that the open portion of the "U" is facing away
(4-19). Tighten Screws (4-19) evenly until the from the major portion of the piston (faces in the
heads contact the Seal Retainer (4-20). The same direction as the Shaft (6-16)). Lightly
Seal Retainer (4-20) is held in place by the lubricate it. Place the assembled Piston (6-14) -
heads of the Screws (4-19). Torque the Screws Shaft (6-16) assembly into the Housing (6-1) and
(4-19) to 14 inch-lbs (16 cm-kg). slowly push it into place until resistance from the
Bal Seal (6-15) is encountered. Continue a
8.2.4 Place the flat Seal (4-28) in the piston cavity of downward even pressure on the parts until the
the Lower Housing Assy (4-10). Insert the Piston (6-14) - Shaft (6-16) assembly is fully into
Washer (4-27) onto the Seal (4-28). Spring (4- the Housing (6-1). It may be wise to use an
26) is next placed to rest on Washer (4-27). "orange stick" (small round stick of hardwood
Carefully guide the Piston Assy (4-18 to 3-23) with a flattened end) to assist in getting the Bal
into the Lower Housing Assy (4-10) and push it Seal (6-15) to evenly enter the Housing (6-1).
with even force until contact is made with
resistance of the seals. Continue even pressure 8.4.3 Lightly lubricate O-Ring (6-9) and insert into
until the Piston Assy (4-18 to 3-23) is fully counter bore in Housing (6-1) and over Shaft (6-
installed such that the Piston Retainer (4-16) can 16). Push into place using O-Ring Retainer (6-
be installed and held in place with the Screws (4- 8). (Note: O-Ring Retainer (6-8) is symmetrical
15). Evenly tighten the Screws (4-15), then and can be inserted either end first).
torque to 23 inch-lbs (26 cm-kg).
8.4.4 Screw Adapter (6-5) onto Shaft (6-16) until it
8.2.5 Push Piston Assy (4-18 to 4-23) open and allow bottoms. Place Spring (6-7) over Shaft (6-16)
it to be closed by the Spring (4-26) several times and onto O-Ring Retainer (6-8). Place Spring
to check for binding that could be caused by Retainer (6-6) into Spring (6-7) and compress
pinched seals. sufficiently to uncover the cross hole in the
Adapter (6-5). Place the Poppet (6-3) into the
8.2.6 If the Cage (shown as a part of the Pilot Valve Adapter (6-5) and align the holes in both the
(1-D, 1-E, 1-F or 1-J)) (5-18 , 6-2, 7-2 or 8-2) or Adapter (6-5) and Poppet (6-3). Push Pin (6-4)
the Valve Stem Assembly (7-7) was removed into the hole and release Spring Retainer (6-6)
from the Lower Half Assy (4-1), replace the O- to retain the Pin (6-4) and Poppet (6-3).
Ring (5-1, 6-11, 7-11, 8-11 or 9-8) and lightly
lubricate it. Install it into the Lower Housing (4-1) 8.4.5 Note that the Cage (5-18, 6-2, 7-2 or 8-2),
and tighten by hand with a wide blade although shown pictorially and furnished as part
screwdriver or in the case of the valve stem of the pilot valves, is assembled into the Lower
assembly use special tool T221790. Half Assy (4-1).

8.3 Servicing Valve (4-3) - Using snap ring pliers, 8.4.6 When ready to install the Pilot Valve (1-E) into
reassemble the Poppet (4-4) onto the Stem (4- the Lower Housing Assy (4-1), install O-ring (6-
6). Install O-Ring (4-9) onto Stem (4-6). Lightly 10) onto Housing (6-1) and carefully insert the
lubricate O-Ring (4-9). Thread this assembly previously assembled parts into the Cage (6-2),
into Poppet Retainer (4-8) until the hole in the installed within the Lower Housing Assy (4-1).
Stem (4-6) is well in the clear. Insert Pin (4-7) Note: When the Pilot Valve (1-E) is procured as
into the hole and with the Stem (4-6) fully a spare part, the Cage (6-2) is furnished as an
supported on a soft surface (block of wood or integral part thereof. Insert Spring (6-13) into
plastic), drive it into place until its ends are Piston (6-14) and place Cover (6-12) onto Spring
approximately equally spaced on each side of (6-13) compressing into place while inserting
the Stem (4-6). Install Gasket (4-2) onto the Screws (6-18) and Washers (6-19). Torque to
Poppet Retainer (4-8) and lightly lubricate it. Set 120 inch-lbs (138 cm-kg).

16
 SM60554 January 2011

8.5 Air Operated Pilot Valve - Defueling (1-J) being certain that the tang of the Latch Bracket
(5-9) is correctly positioned to enter the Housing
8.5.1 Carefully install the Bal Seal (6-15) onto the (5-2) slot. Tap Pins (5-8) into the Housing (5-2),
Piston (6-14) being certain that the open portion through the Latch Bracket, (5-9) until Pins (5-8)
of the "U" is facing away from the major portion are bottomed. Slide Cable Assy (5-10) through
of the piston (faces in the same direction as the hole in Latch Bracket (5-9), Latch Stop (5-11)
Shaft (6-16)). Lightly lubricate it. If Shaft (6-16) and Spring (5-12), then through the appropriate
was removed it should be reinstalled hole in the Housing (5-2). Check, by pulling and
releasing Cable Assy (5-10), to confirm that
8.5.2 Place one Wave Washers (6-25) into the piston
there is free movement of the Latch Bracket
bore of the Housing (6-1), then Washers (6-26)
against the Spring (5-12). Place Hose (5-13) into
followed by the other Wave Washers (6-25).
position and retain with Clamp (5-14). If a
8.5.3 Place the assembled Piston (6-14) - Shaft (6- suitable tool is available, the production Clamp
16) assembly into the Housing (6-1) and slowly (5-15) can be used. A suggested tool is made by
push it into place until resistance from the Bal National Telephone Supply Co., stock number
Seal (6-15) is encountered. Continue a 51-X-850 or equivalent. Thread the free end of
downward, even pressure on the parts until the the Cable Assembly (5-10) through the Clamp
Piston (6-14) - Shaft (6-16) assembly is fully into (5-15). Bend Cable Assy (5-10) to form a
the Housing (6-1). It may be wise to use an suitable loop in the free end. Thread the free end
"orange stick" (small round stick of hardwood of the Cable Assy (5-10) back into the Clamp (5-
with a flattened end) to assist in getting the Bal 15) and crimp in place. If a suitable tool is not
Seal (6-15) to evenly enter the Housing (6-1). available, use alternative Clamp (5-15A) which
utilizes two screws to retain the loop.
8.5.4 Lightly lubricate O-Ring (6-9) and insert into
counter bore in Housing (6-1) and over Shaft (6- 8.6.2 Place Spring (5-3) over Latch Spool (5-4) and
16). Push into place using O-Ring Retainer (6- insert Latch Spool (5-4) into Housing (5-2). Note
8). (Note: O-Ring Retainer (6-8) is symmetrical that the Latch Bracket (5-9) will have to be
and can be inserted either end first). pulled out of the way by pulling upon the Cable
Assy (5-10) while attempting to do this
8.5.5 Screw Adapter (6-5) onto Shaft (6-16) until it operation. Place Latch Cover (5-5) over Latch
bottoms. Place Spring (6-7) over Shaft (6-16) Spool (5-4) such that the large open end
and onto O-Ring Retainer (6-8). Place Spring protrudes over the Housing (5-2). If Ball (5-6A) is
Retainer (6-6) into Spring (6-7) and compress to be replaced, tap it onto the end of Handle (5-
sufficiently to uncover the cross hole in the 6) that is farthest from the cross hole. Place
Adapter (6-5). Place the Poppet (6-3) into the Handle (5-6) over Latch Spool (5-4) and align
Adapter (6-5) and align the holes in both the holes. With adequate support for the parts, tap
Adapter (6-5) and Poppet (6-3). Push Pin (6-4) Pin (5-7) to retain assembly.
into the hole and release Spring Retainer (6-6)
to retain the Pin (6-4) and Poppet (6-3) 8.6.3 Pull Handle (5-6) and observe that the Latch
Bracket (5-9) latches onto the Latch Spool (5-4).
8.5.6 Note that the Cage (5-18, 6-2, 7-2 or 8-2), Pull the Cable Assy (5-10) to release the Latch
although shown pictorially and furnished as part Spool (5-4).
of the pilot valves, is assembled into the Lower
Half Assy (4-1). 8.6.4 While applying pressure to the Cable Assy (5-
10) to keep the Latch Bracket (5-9) clear of the
8.5.7 When ready to install the Pilot Valve (1-J) into Latch Spool (5-4) and Spring (5-3), Push Handle
the Lower Housing Assy (4-1), install O-ring (6- (5-6) inward to force the Latch Spool (5-4) out of
10) onto Housing (6-1) and carefully insert the Housing (5-2) sufficiently to align Shaft (5-16)
previously assembled parts into the Cage (6-2), with Latch Spool (5-4) and install Pin (5-17).
installed within the Lower Housing Assy (4-1).
Note: When the Pilot Valve (1-J) is procured as 8.6.6 Place Pilot Retainer (5-27) over Shaft (5-16) and
a spare part, the Cage (6-2) will be furnished as move into groove in Housing (5-2). Lightly
an integral part thereof. Insert Wear Plate (6-20) lubricate O-Ring (5-26) and insert into counter
and Spring (6-13) into Piston (6-14) and place bore in Pilot Retainer (5-27) and over Shaft (5-
Cover (6-12) with Screw (6-23) and Pin (6-24) 16). Push into place using O-Ring Retainer (5-
installed onto Spring (6-13) compressing into 25). (Note: O-Ring Retainer (5-25) is
place while inserting Screws (6-18) and Washers symmetrical and can be inserted either end first).
(6-19). Torque to 120 inch-lbs (138 cm-kg). If
8.6.7 Screw Adapter (5-21) onto Shaft (5-16) until it
Screw (6-23) and Pin (6-24) were removed for
bottoms. Place Spring (5-24) over Shaft (5-16)
replacement, reinstall prior to placing Cover (6-
and onto O-Ring Retainer (5-25). Place Spring
22) into place.
Retainer (5-23) into Spring (5-24) and compress
8.6 Lanyard Operated Pilot Valve (1-D) sufficiently to uncover the cross hole in the
Adapter (5-21). Place the Poppet (5-22) into the
8.6.1 With Housing (5-2) in a suitable vise, being Adapter (5-21) and align the holes in both the
careful not to damage part, place Latch Bracket Adapter (5-21) and Poppet (5-22). Push Pin (5-
(5-9) over corresponding holes in Housing (5-2)

17
 SM60554 January 2011

20) into the hole and release Spring Retainer (5- 8.8.2 If the Cable Assembly (8-41) was cut, replace with
23) to retain the Pin (5-20) and Poppet (5-22). new part pulling it through the Cable Retainer (8-
34). Insert Ball Retainer (8-33) into Cable
8.6.8 Note that the Cage (5-18, 6-2, 7-2 or 8-2), Retainer (8-34). Install Spring (8-31) into Ball
although shown pictorially and furnished as part Retainer (8-33). Assemble these parts into
of the pilot valves, is assembled into the Lower Housing (8-35) and hold in compressed position
Half Assy (4-1). Install O-ring (5-19) onto Pilot to insert Balls (8-32). Install these parts into
Retainer (5-27) and carefully insert the above Connector (8-23). Screw on Lanyard Guide (8-
assembled parts into the Cage (5-18) and align 30). Align holes in items (8-33) and (8-34) with
the mounting holes with the appropriate holes in slots in (8-30). Press in Pin (8-22).
the Lower Housing Assy (4-1). Fasten in place
with Screws (5-29) and Washers (5-28). Tighten 8.8.3 Insert Poppet (8-25) into Shaft (8-29) and align
evenly and then torque to 120 inch-lbs (138 cm- hole for insertion of Pin (8-27). Hold in place by
kg). installing Retainer (8-26). Place Spring (8-28)
over Retainer (8-26) and insert items into the
8.7 Air/Lanyard Pilot Valve (1-F) open end of Connector (8-23). Align holes and
insert second Pin (8-22) to retain in place. Pull
8.7.1 Reassemble in the reverse order of disassembly
Cable (8-41) to open unit and not allow damage
noting the following:
to Poppet (8-25) during the next installation
8.7.2 If the Cable Assembly (7-40) was cut, replace procedure. Insert assembly into Housing (8-1)
with new part pulling it through the Cable and secure with Screws (8-20).
Retainer (7-33). Insert Ball Retainer (7-32) into
8.8.4 Slide Reset Ring (8-37) over cable with lettering
Cable Retainer (7-33). Install Spring (7-30) into
visible toward the cable. Install Retaining Ring
Ball Retainer (7-32). Assemble these parts into
(8-36) into the groove in Lanyard Guide (8-30) to
Housing (7-34) and hold in compressed position
retain. Slip Hose (8-42) over end of Lanyard
to insert Balls (7-31). Install these parts into
Guide and retain in place with Clamp (8-40). If a
Connector (7-22). Screw on Lanyard Guide (7-29).
suitable tool is available, the production Clamp
Align holes in items (7-32) and (7-33) with slots in
(8-40) can be used. A suggested tool is made by
(7-29). Press in Pin (7-21).
National Telephone Supply Co., stock number
8.7.3 Insert Poppet (7-24) into Shaft (7-28) and align 51-X-850 or equivalent. Thread the free end of
hole for insertion of Pin (7-26). Hold in place by the Cable (8-41) through the Clamp (8-40). Bend
installing Retainer (7-25). Place Spring (7-27) Cable (8-41) to form a suitable loop in the free
over Retainer (7-25) and insert items into the end. Thread the free end of the Cable (8-41)
open end of Connector (7-22). Align holes and back into the Clamp (8-40) and crimp in place. If
insert second Pin (7-21) to retain in place. Pull a suitable tool is not available, use alternative
Cable (7-40) to open unit and not allow damage to Clamp (8-40A) which utilizes two screws to
Poppet (7-24) during the next installation retain the loop.
procedure. Screw in Seat (7-23) to a bottomed 8.8.5 Assemble the air piston section in accordance
position. with paragraphs 8.4.
8.7.4 Slide Reset Ring (7-36) over cable with lettering 8.9 Option “X” Air/Lanyard Pilot Valve Connector
visible toward the cable. Install Retaining Ring Assembly (1-X) - Valve Stem Assembly (9-7) – If
(7-35) into the groove in Lanyard Guide (7-29) to this item was fully disassembled, first replace
retain. Slip Hose (7-41) over end of Lanyard Stem (9-11) into the Cage (9-12). Then insert
Guide and retain in place with Clamp (7-39). If a the Spring (9-10) into the cavity in the stem and
suitable tool is available, the production Clamp place the Spring Guide (9-9) keeping the flat
(7-38) can be used. A suggested tool is made by surface on the outside. Press the spring guide
National Telephone Supply Co., stock number into the cage to retain. Place the O-ring (9-8)
51-X-850 or equivalent. Thread the free end of onto the cage. Lubricate the o-ring and insert
the Cable Assembly (7-40) through the Clamp the assembly into the lower valve housing.
(7-38). Bend Cable Assy (7-40) to form a
suitable loop in the free end. Thread the free end Lubricate and replace O-ring (9-3) into its groove
of the Cable Assy (7-40) back into the Clamp (7- inside of the Connector (9-2). Lubricate and
38) and crimp in place. If a suitable tool is not place O-ring (9-4) on the shoulder of the
available, use alternative Clamp (7-38A) which connector. Install the connector onto the lower
utilizes two screws to retain the loop. housing and retain using Screws (9-5) and
Washers (9-6). Insert a ¼” plastic rod into he
8.7.5 Assemble the air piston section in accordance connector and push the stem downward to its
with paragraphs 8.4. stop. Release the rod and observe that the stem
retracts.
8.8 Air/lanyard Pilot Valve (1-U)
8.10 Final Assembly
8.8.1 Reassemble in the reverse order of disassembly
8.10.1 With Lower Half Assy (4-1) set up such that the
noting the following:
piston (inlet) is against the work bench, insert
the Strainer (2-21) as applicable.

18
 SM60554 January 2011

8.10.2 Lightly lubricate and place O-Ring (2-22) into the 8.10.5 If Product Selection Assy (1-C) was removed,
groove in the Lower Half Assy (4-1). replace it. Note that the position of selection
desired is achieved by placing one of the set of
8.10.3 Be sure that the Stem (4-6) of the Servicing Bolts (1-3) and stack of Washers (1-4 & 1-6) in
Valve (4-3) is fully screwed out, install the the hole numbered to the position. The other two
Servicing Valve (4-3) into the Lower Half Assy selection sets are always located in the two un-
(4-1). Torque to 100-110 ft lbs (13.83 to 15.21 numbered holes. It should be noted also that the
m-kg). Do not over tighten. (Some valves were four Bolts (1-5) and Standoffs, (1-2) used to
wire locked at the factory, but later versions mount the product selector, replace the same
substituted this torque requirement for the wire number of Screws (2-3) and Washers (2-4).
locking.)
8.10.6 Installation of the 60554 onto the mating flange
8.10.4 Place the Upper Half Assy (2-6) onto the Lower should be done by loosely tightening the
Half Assy (4-1) such that the notch in the mating mounting bolts evenly. The bolts should then
flange is located opposite to the pilot valve boss. torqued in a normal cross pattern in three
The one shorter Screw (2-5) is to be installed in successive steps. If the bolt pattern is numbered
the hole just to the left of the pilot valve boss. 1 through 8 in a clockwise fashion, tighten in
Install Screws (2-3 & 2-5) and Washers (2-4) sequence 1,5,3,7,2,6,4 and 8. The torque for the
making sure that the Cover (2-23) is attached to three steps should be 40 ft-lbs (5.5 m-kg), 70 ft-
one of the Screws (2-3). If product selection is lbs (9.7m-kg) and 93 ft-lbs (12.9 m-kg).
used see paragraph 8.8.5 before completing this
section. Tighten evenly and then torque to 120 8.10.7 Service Manual SM47076 covers the installation
inch-lbs (138 cm-kg). of the 60554 into a 12 or 13-inch Avery Hardoll
pit using option N of the 60554.

9.0 TEST

9.1 Test conditions Valve (1-D, 1-E, 1-F, 1-J or 1-U) or on Option “X”
attach either the 64230 or 64231 Actuator
Test media shall be JP-4, Jet A or odorless Assembly and open the Valve Connector
kerosene, commercial solvent 140. Assembly (1-X). Apply 300 psig for one minute
and observe for leakage. The Servicing Valve
9.2 Functional Test
(4-3) shall not open and there shall be no
The valve must be connected to a fluid pressure evidence of leakage as evidenced by leakage
source with capability of static pressure of 300 through the Poppet (2-11).
psig, flow pressure (deadhead) of 120 psig and
9.2.4 Flow Tests - Install the valve in high flow test
a flow rate of up to 1,100 USGPM. For the air
stand. Connect the outlet of the unit to a Carter
operated units, a minimum of 120 psig air
61525 Coupler. Open Pilot Valve (1-D, 1-E, 1-F,
pressure must be available.
1-J or 1-U) or on Option “X” attach either the
9.2.1 Leakage & Proof Pressure - Attach valve to a 64230 or 64231 Actuator Assembly and open
static fuel pressure source of 300 psig minimum. the Valve Connector Assembly (1-X). With 120
Open Pilot Valve (1-D, 1-E, 1-F, 1-J or 1-U) or psig deadhead pressure establish a flow rate of
on Option “X” attach either the 64230 or 64231 1100 USGPM.
Actuator Assembly and open the Valve
9.2.4.1 Close the Pilot Valve (1-D, 1-E, 1-F, 1-J or 1-U)
Connector Assembly (1-X), open Servicing
or remove the Actuator Assembly (Option “X”)
Valve (4-3) and fill valve manually opening the
and observe closing time and overshoot.
Pressure Equalization Poppet (2-13) in the outlet
Overshoot is defined as the volume of fluid that
Poppet (2-11) to allow trapped air to escape.
passes through the valve after the pilot valve
Blow the external wetness off of the valve and
has been closed. Closing time shall be 2 to 5
pressurize the unit to 25 psig and 300 psig for a
seconds and overshoot shall be less than 55
minimum of one minute at each pressure and
gallons at 1,100 USGPM.
observe for external leakage. There should be
no leakage. 9.2.4.2 Opening Time - Using the same test setup, start
with a closed valve and 120 psig deadhead
9.2.2 Seal Leakage - With the unit in the same test
pressure, open Pilot Valve (1-D, 1-E, 1-F, 1-J or
setup, close pilot valve or remove the Actuator
1-U) or on Option “X” attach either the 64230 or
Assembly (Option “X”) and block the outlet
64231 Actuator Assembly and open the Valve
Poppet open with a soft plastic rod (see
Connector Assembly (1-X) and observe opening
paragraph 6.1 for hint). Apply 25 and 300 psig
time. Opening time is defined as the time
for one minute at each pressure and observe for
required for the valve to achieve at least 90% of
leakage as evidenced by fuel flow out of Poppet
rated flow, 990 USGPM in this case. The
(2-11). There shall be no leakage from unit.
opening time shall be 5 to 10 seconds.
9.2.3 Servicing Valve Leakage - With the same test
setup, close Servicing Valve (4-3) and open Pilot

19
 SM60554 January 2011

10.0 TROUBLE SHOOTING

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

11.0 ILLUSTRATED PARTS CATALOG

Tables 1.0 through 9.0 tabulate the parts comprising the various configurations and options of the 60554 Series
of Hydrant Valves. The item numbers are keyed to the appropriate exploded view for the option or sub-
assembly as diagrammed.

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 SM60554 January 2011

TABLE 1
60554 Series Hydrant Valve and Options
Figure 1

Units/ Hydrant Spares/10

Fig. Item Part Number Description Assy Option Units/Yr.
1 C 44290 Product Selection Ring Assy 1 C -
1 207721 Ring 4 C -
2 207722 Standoff 4 C -
3 GF6-13 Bolt 3 C -
4 GF960-616L Washer 3 C -
5 GF5-35 Bolt 4 C -
6 GF960-616 Washer 27 C -
7 GF21083N6 Nut 3 C -
D 44248 Lanyard Pilot Valve 1 D -
42836 Lanyard Pilot Valve (Obsolete) - - -
E 44721 Pilot Valve, Air Operated 1 E -
44247 Pilot Valve (Obsolete) - E -
42846 Pilot Valve (Obsolete) - E -
F 47091-1 Pilot Valve, Dual Air/lanyard for small pits 1 F -
X 47576 Valve Connector Assy 1 X
G 44364 6 X 4" IP Spool Assy 1 G -
10 207742 Adapter 1 G -
11 82154 Gasket 1 G -
12 82155 Bolt 8 G -
13 82156 Nut 8 G -
14 GF960-1016 Washer 16 G -
H 43587 Stone Guard Assy 1 H -
8 203331 Stone Guard 1 H -
9 RR-637-S Retaining Ring 1 H -
J 44570 Pilot Valve, Defueling 1 J -
K 44744 12" Pit Spool Assy 1 K -
11 82154 Gasket 1 K -
13 82156 Nut 8 K -
14 GF960-1016 Washer 8 K -
15 210341 Spool 1 K -
16 210384-36 Stud 8 K -
L 44745 13" Pit Spool Assy 1 L -
11 82154 Gasket 1 L -
13 82156 Nut 8 L -
14 GF960-1016 Washer 8 L -
16 210384-36 Stud 8 L -
17 210342 Spool 1 L -
M 44731 Quick Disconnect Assy 1 M -
18 B2K16-VB Male QD Fitting 1 M -
19 220013-01 Close Nipple 1 M -
- 47709 Dust Cap 1 M -
20 47077 Adapter Kit, Option N installation 1 N -
21 47075 Adapter 1 N -
22 220345 Stud 8 N -
23 82156 Nut 8 N -
24 GF960-1016 Washer 8 N -
25 GF16997-171 Bolt 4 N -
26 5712-403-63 Washer 4 N -

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 SM60554 January 2011

Units/ Hydrant Spares/10

Fig. Item Part Number Description Assy Option Units/Yr.
1 27 MS29513-232 O-ring 2 N -
28 220343 Plate 1 N -
29 220342 Plate 1 N -
30 MS29513-237 O-ring (alternative to 31) 1 N -
31 220344 Gasket (alternative to 30) 1 N -
32 MS29513-246 O-ring 1 N 10
P 47199 6 X 4" Short (4”) Spool Assy 1 P -
10 220965 Adapter 1 P -
11 82154 Gasket 1 P -
12 210384-22 Stud 8 P -
13 82156 Nut 8 P -
14 GF960-1016 Washer 16 P -
T 47326 Fusible Plug 1 T -
U 47361-1 Pilot Valve, Dual Air/lanyard large pit 1 U -

FIGURE 1
60554 SERIES HYDRANT VALVE OPTIONS

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 SM60554 January 2011

TABLE 2
Upper Housing Assy, Options A and B - Figure 2

Units/ Hydrant Spares/10

Fig. Item Part Number Description Assy Option Units/Yr.
2 3 GF16998-60 Screw 7 All but S -
GF16998-33 Screw 7 S -
4 GF960-516 Washer 8 All -
5 GF16996-32 Screw 1 All -
6A 47203-1 Upper Half Assy, 2-piece std. aluminum/st. st. 1 All but Q, R, S -
7 47159-1 Upper Housing Assy (See Table 3 for parts) 1 All but Q, R, S -
8 43795 Poppet Assy 1 All -
11 210284 Poppet - Steel 1 All -
200848-1 Poppet – Obsolete, aluminum (Note 7) 1 All 1
12 221170 Seal 1 All 10
13 200011 Poppet, Pressure Equalization 1 All 2
14 200014 Spring 1 All -
15 200012 Retainer 1 All -
16 200849 Shroud 1 All -
17 RS-156-S Retaining Ring 1 All -
9 29472 Seal Ring 1 All 1
10 29486 Seal 1 All 10
18 28618 Spring 1 All -
19 200847 Retainer, Poppet 1 All -
6B 43214 Upper Half Assy, 1-piece ductile iron 1 Q -
8 43795 Poppet Assy 1 All -
11 210284 Poppet - Steel 1 All -
200848-1 Poppet – Obsolete, aluminum (Note 7) 1 All 1
12 221170 Seal 1 All 10
13 200011 Poppet, Pressure Equalization 1 All 2
14 200014 Spring 1 All -
15 200012 Retainer 1 All -
16 200849 Shroud 1 All -
17 RS-156-S Retaining Ring 1 All -
18 28618 Spring 1 All -
19 200847 Retainer, Poppet 1 All -
6C 47203-2 Upper Half Assy, 2-piece ductile/st. steel. 1 R -
47159-2 Housing Assembly, ductile iron/st st 1 R -
(See Table 3 for parts)
8 43795 Poppet Assy 1 All -
9 29472 Seal Ring 1 All 1
10 29486 Seal 1 All 10
11 210284 Poppet - Steel 1 All -
200848-1 Poppet – Obsolete, aluminum (Note 7) 1 All 1
12 221170 Seal 1 All 10
13 200011 Poppet, Pressure Equalization 1 All 2
14 200014 Spring 1 All -
15 200012 Retainer 1 All -
16 200849 Shroud 1 All -
17 RS-156-S Retaining Ring 1 All -
9 29472 Seal Ring 1 All 1
10 29486 Seal 1 All 10
18 28618 Spring 1 All -
19 200847 Retainer, Poppet 1 All -
6D 43214-4 Upper Half Assy, stainless 1 S -
7 29279-5 Upper Housing 1 S -
8 43795 Poppet Assy 1 All -
11 210284 Poppet - Steel 1 All -

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 SM60554 January 2011

Units/ Hydrant Spares/10

Fig. Item Part Number Description Assy Option Units/Yr.
2 200848-1 Poppet – Obsolete. Aluminum (Note 7) 1 All 1
12 221170 Seal 1 All 10
13 200011 Poppet, Pressure Equalization 1 All 2
14 200014 Spring 1 All -
15 200012 Retainer 1 All -
16 200849 Shroud 1 All -
17 RS-156-S Retaining Ring 1 All -
9 29472 Seal Ring 1 All 1
10 29486 Seal 1 All 10
18 28618 Spring 1 All -
19 200847 Retainer, Poppet 1 All -
20 29288 Ring Retainer 1 All -
21 81557-10 Strainer, 10-mesh 1 A -
81557-20 Strainer, 20-mesh 1 B -
22 MS29513-165 O-Ring 1 All 10
23 41579 Cover Assy 1 All 3
1 28622 Cover 1 All 3
2 - Cable Assy (Note 3) 1 All -
24 5758-21C2 Washer, Retaining 1 All -

FIGURE 2 - UPPER HALF & OPTIONS A & B

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 SM60554 January 2011

TABLE 3.0
Standard and Option R Upper Half Assembly - Figure 3

Units/ Spares/10
Fig. Item Part Number Description Assy Hydrant Option Units/Yr.
3 1 47159-1 Housing Assembly, Aluminum/St. Steel 1 All but Q, R & S -
47159-2 Housing Assembly, Ductile Iron/St. Steel 1 R -
2 221289 Housing, aluminum 1 All but Q, R & S -
220844-2 Housing, Ductile Iron 1 R -
3 221118 O-ring 1 All but Q & S 10
4 220856 Ring, Coupler Connecting 1 All but Q & S 1
5 NAS1352N3-8 Screw 20 All but Q & S -
6 5710-159-16 Washer 20 All but Q & S -
7 603 Locktite, 10 ml. A/R All but Q & S 1

FIGURE 3 - 2-PIECE UPPER HALF

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 SM60554 January 2011

TABLE 4.0
Lower Half Assy - Figure 4

Units/ Hydrant Spares/10

Fig. Item Part Number Description Assy Option Units/Yr.
4 1 43219 Lower Half Assy 1 All but J -
44292 Lower Half Assy 1 J -
2 MS29512-12 Gasket 1 All 10
3 43272 Servicing Valve 1 All -
4 202597 Poppet 1 All 2
5 5008-62-H Retainer 1 All -
6 202631 Stem 1 All -
7 .156-1.000MDP Pin 1 All -
8 202630 Retainer, Poppet 1 All -
9 MS29513-010 O-Ring 1 All 10
10 42927 Lower Housing Assy 1 All -
11 202556 Lower Housing (Note 3) 1 All -
12 202593 Shaft (Note 3) 1 All -
13-14 Left intentionally blank
15 NAS517-3-3 Screw 6 All -
16 202596 Retainer, Piston 1 All -
17 MS29513-249 O-Ring 1 All 10
18 202592 Piston 1 All Note 4
19 GF51958-62 Screw 6 All -
20 203032 Retainer, Piston Seal 1 All but J -
207727 Retainer, Piston Seal 1 J -
21 210127 Seal, Piston 1 All 10
22 MS29513-118 O-Ring 1 All 10
23 203030 Seal, Slipper 1 All 10
24 MS29513-245 O-Ring 1 All 10
25 202594 Seal, Slipper 1 All 10
26 202595 Spring 1 All -
27 203029 Washer 1 All -
28 203028 Seal 1 All 10
29 29224-7 Orifice 1 All -

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 SM60554 January 2011

FIGURE 4 - LOWER HALF ASSEMBLY (4-1)

27
 SM60554 January 2011

TABLE 5.0
Lanyard Operated Pilot Valve - Figure 5

Units/ Hydrant Spares/10

Fig. Item Part Number Description Assy Option Units/Yr.
5 D 44248 Lanyard Pilot Valve 1 D Note 4
42836 Lanyard Pilot Valve (Obsolete) - - -
1 201201-014 O-Ring 1 All 10
2 202704 Housing 1 D -
3 202714 Spring 1 D -
4 202706 Spool, Latch 1 D -
5 202705 Cover, Latch 1 D 5
6 203533 Handle 1 D -
6A 47084 Ball 1 D -
7 GF16562-234 Pin 1 D -
8 GF51923-297 Pin 2 D -
9 202716 Bracket, Latch 1 D -
10 42954 Cable Assy 1 D -
11 202717 Stop, Release 1 D -
12 202715 Spring, Release 1 D -
13 81052 Hose 1 D 1
14 81094 Clamp, Hose 1 D -
15 82114 Sleeve 1 D -
15A 81095 Clamp, Cable 1 D -
16 207589 Shaft 1 D -
17 202743 Pin 1 D -
18 207718 Cage 1 All -
19 MS29513-114 O-Ring 1 All 10
20 GF9105-04 Pin 1 All 2
21 44252 Adapter 1 All -
22 207585 Poppet 1 All 5
23 207586 Retainer 1 All -
24 202712 Spring 1 All -
25 202742 Retainer, O-ring 1 All 2
26 201201-008 O-Ring 1 All 10
27 202708 Retainer, Pilot Valve 1 D -
28 GF960-516 Washer 2 D -
29 GF35308-333 Bolt 2 D -

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 SM60554 January 2011

FIGURE 5 - LANYARD OPERATED PILOT VALVE

29
 SM60554 January 2011

TABLE 6.0
Air Operated Pilot Valves, Options E & J - Figure 6
Units/ Hydrant Spares/10
Fig. Item Part Number Description Assy Option Units/Yr.
6 E 44721 Pilot Valve, Air Operated 1 E Note 4
44247 Pilot Valve (Obsolete) - E -
42846 Pilot Valve (Obsolete) - E -
1 47106 Housing (Newer Valves) 1 E -
208967 Housing (Obsolete) - E -
207600 Housing (Obsolete) - E -
2 207718 Cage 1 All -
3 207585 Poppet 1 All 5
4 GF9105-04 Pin 1 All 2
5 44252 Adapter 1 All -
6 207586 Retainer 1 All -
7 202712 Spring 1 All -
8 202742 Retainer, O-ring 1 All -
9 201201-008 O-Ring 1 All 10
10 MS29513-114 O-Ring 1 All 10
11 201201-014 O-Ring 1 All 10
12 207598 Cover 1 E -
13 207706 Spring 1 E, J -
14 44571 Piston 1 E, J -
44253 Piston (Obsolete) 1 E -
15 221290 Seal 1 E, J 10
16 207588 Shaft 1 E, J -
17 210176 Spacer 1 E -
18 GF16998-63 Screw 2 E, J -
19 GF960PD516 Washer 2 E, J -
J 44570 Pilot Valve, Defueling 1 J Note 4
1 47106 Housing (Newer Valves) 1 J -
208967 Housing (Obsolete) - E, J -
2 207718 Cage 1 All -
3 207585 Poppet 1 All 5
4 GF9105-04 Pin 1 All 2
5 44252 Adapter 1 All -
6 207586 Retainer 1 All -
7 202712 Spring 1 All -
8 202742 Retainer, O-ring 1 All -
9 201201-008 O-Ring 1 All 10
10 MS29513-114 O-Ring 1 All 10
11 201201-014 O-Ring 1 All 10
13 207706 Spring 1 E, J -
14 44571 Piston 1 E, J -
15 221290 Seal 1 E, J 10
16 207588 Shaft 1 E, J -
18 GF16998-63 Screw 2 E, J -
19 GF960PD516 Washer 2 E, J -
20 208958 Wear Plate 1 J -
21 47370 Screw Assembly 1 J -
22 221312 Cover 1 J -
208968 Cover (Obsolete) - J Note 6
23 221313 Screw 1 J
208959 Screw (Obsolete) - J Note 6
24 GF16562-213 Pin - J -
25 SSR0150-S17 Wave Washer 2 J -
26 5710-355-30 Washer 1 J -
27 5406-P-04 Plug 1 E, J -

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 SM60554 January 2011

FIGURE 6 - AIR OPERATED PILOT VALVES

31
 SM60554 January 2011

Table 7.0
Air/Lanyard Operated Pilot Valve, Option F

Units/ Hydrant Spares/10

Fig. Item Part Number Description Assy Option Units/Yr.
7 1-FM 47091-1 Air/Lanyard Pilot w/option M (Note 5) 1 FM -
1-F 47091-2 Air/Lanyard Pilot (Note 5) 1 F -
1 47106 Housing 1 F, FM -
2 207718 Cage 1 All -
3 207585 Poppet 1 All 5
4 GF9105-04 Pin 1 All 2
5 44252 Adapter 1 All -
6 207586 Retainer 1 All -
7 202712 Spring 1 All -
8 202742 Retainer, O-ring 1 All -
9 201201-008 O-Ring 1 All 10
10 MS29513-114 O-Ring 1 All 10
11 201201-014 O-Ring 1 All 10
12 207598 Cover 1 F, FM -
13 207706 Spring 1 F, FM -
14 44571 Piston 1 F, FM -
15 221290 Seal 1 F, FM 10
16 207588 Shaft 1 F, FM -
17 210176 Spacer 1 F, FM -
18 GF16998-63 Screw 2 F, FM -
19 GF960-516 Washer 2 F, FM -
20 47093 Valve Assembly 1 F, FM -
21 .125-1.250LDP Pin 2 F, FM -
22 220410 Connector 1 F, FM -
23 220407 Seat 1 F, FM -
24 207585 Poppet 1 F, FM 5
25 207586 Retainer 1 F, FM -
26 GF9105-04 Pin 1 F, FM -
27 10460 Spring 1 F, FM -
28 220408 Shaft 1 F, FM -
29 220474 Lanyard Guide 1 F, FM -
30 C0210-026-125S Spring 1 F, FM -
31 220417 Ball 3 F, FM -
32 220412 Ball Retainer 1 F, FM -
33 220411 Cable Retainer 1 F, FM -
34 220409 Housing 1 F, FM -
35 220489 Retaining Ring 1 F, FM -
36 220475 Reset Ring 1 F, FM -
37 No Part Number Cable Assembly 1 F, FM -
38 82114 Sleeve 1 F, FM -
38A 81095 Clamp Assy (See 5-15A) 1 F, FM -
39 81094 Clamp 1 F, FM -
40 42954 Cable 1 F, FM 1
41 81052 Hose 1 F, FM 1

32
 SM60554 January 2011

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

33
 SM60554 January 2011

Table 8.0
Air/Lanyard Operated Pilot Valve, Option U

Units/ Hydrant Spares/10

Fig. Item Part Number Description Assy Option Units/Yr.
8 1-U 47361-1 Air/Lanyard Pilot Valve 1 U -
1-MU 47361-2 Air/Lanyard Pilot Valve w/Option M 1 MU -
1 47359 Housing 1 MU, U -
2 207718 Cage 1 All -
3 207585 Poppet 1 All 5
4 GF9105-04 Pin 1 All 2
5 44252 Adapter 1 All -
6 207586 Retainer 1 All -
7 202712 Spring 1 All -
8 202742 Retainer, O-ring 1 All -
9 201201-008 O-Ring 1 All 10
10 MS29513-114 O-Ring 1 All 10
11 201201-014 O-Ring 1 All 10
12 207598 Cover 1 MU, U -
13 207706 Spring 1 MU, U -
14 44571 Piston 1 MU, U -
15 221290 Seal 1 MU, U 10
16 207588 Shaft 1 MU, U -
17 210176 Spacer 1 MU, U -
18 GF16998-63 Screw 2 MU, U -
19 GF960-516 Washer 2 MU, U -
20 GF16997-45 Screw 3 MU, U -
21 47360 Valve Assembly 1 MU, U -
22 .125-1.000LDP Pin 1 MU, U -
23 221275 Connector 1 MU, U -
24 207585 Poppet 1 MU, U 5
25 207586 Retainer 1 MU, U -
26 GF9105-04 Pin 1 MU, U -
27 10460 Spring 1 MU, U -
28 220408 Shaft 1 MU, U -
29 .125-1.250LDP Pin 1 MU, U 10
30 220474 Lanyard Guide 1 MU, U -
31 C0210-026-125S Spring 1 MU, U -
32 220417 Ball 3 MU, U -
33 220412 Ball Retainer 1 MU, U -
34 220411 Cable Retainer 1 MU, U -
35 220409 Housing 1 MU, U -
36 220489 Retaining Ring 1 MU, U -
37 220475 Reset Ring 1 MU, U -
38 No Part Number Cable Assembly 1 MU, U -
39 82114 Sleeve 1 MU, U -
40A 81095 Clamp Assy (See 5-15A) 1 MU, U -
40 81094 Clamp 1 MU, U -
41 42954 Cable Assy 1 MU, U 1
42 81052 Hose 1 MU, U 1

34
 SM60554 January 2011

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

35
 SM60554 January 2011

Table 9
Connector Valve Assembly – Figure 9

Units/ Hydrant Spares/10

Fig. Item Part Number Description Assy Option Units/Yr.
9 1-X 47576 Air/Lanyard Pilot Valve Connector Assembly 1 X -
1 47574 Connector Assembly 1 X -
2 221791 Connector 1 X -
3 M25998/1-012 O-ring 1 X 10
4 MS29513-114 O-ring 1 X 10
5 GF35308-330 Screw 2 X -
6 GF960-516 Washer 2 X -
7 47573 Valve Stem Assembly 1 X -
8 201201-014 O-ring 1 X 10
9 221792 Spring Guide 1 X -
10 K-30 Spring 1 X -
11 221789 Stem 1 X -
12 221790 Cage 1 X -

RETROFIT INFORMATION

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

1. Order one 47576 Valve Connector Assembly (for air/fuel operation) kit (shown to the right) for each hydrant
valve.
2. Order special tool T221790 (only one per airport is needed).
3. Remove and discard the existing pilot valve and cage from the hydrant valve.
4. Using the special tool screw the cage into the hydrant valve body.
5. Once the 48573 is seated and tightened install the 47574 Connector Assembly using the two screws provided.
6. Retrofit the hydrant servicers by ordering one each 64230 or 64231 Actuator Assembly as appropriate to your
operation for each servicer. Replace the existing disconnect on the hose to the hydrant valve with the
64230/64231 as appropriate. It is recommended that at least one spare 64230 or 64231 Actuator Assembly be
ordered for each airport.

36
 SM60554 January 2011

FIGURE 9 - AIR/FUEL PILOT VALVE CONNECTOR ASSEMBLY – OPTION “X”

37
 SM60554 January 2011

Table 10
KITS for Maintenance
The following kits are available for maintaining the units as noted:

KIT NUMBER DESCRIPTION - CONTENTS COMMENTS

KD60554-1 This kit is for use in repairing/overhauling any 60554 Hydrant Valve Replaces KD60554 Kit.
less the Pilot Valve and contains 2-10, 2-12, 2-22, 3-3, 4-2, 4-4,
4-9, 4-17, 4-21, 4-22, 4-23, 4-24, 4-25 & 4-28.

KD60554-2 This kit is for use in repairing a complete 60554D Hydrant Valve
including the Lanyard Operated Pilot Valve and contains 2-10, 2-12,
2-22, 3-3, 4-2, 4-4, 4-9, 4-17, 4-21, 4-22, 4-23, 4-24, 4-25, 4-28,
5-1, 5-5, 5-19, 5-22 & 5-26 .

KD60554-3 This kit is for use in repairing a complete 60554E or 60554J Hydrant
Valve including either the Air Operated Pilot Valves with or without
the defueling option and contains 2-10, 2-12, 2-22, 43-3, -2, 4-4, 4-9,
4-17, 4-21, 4-22, 4-23, 4-24, 4-25, 4-28, 6-3, 6-9, 6-10,
6-11, 6-13 & 6-15.

KD60554-4 This kit is for use in repairing older Hydrant Valves with obsolete For 60554D Valves with obsolete
42836 Pilot Valve and contains 2-10, 2-12, 2-22, 3-3, 4-2, 4-4, 4-9, 42836 Pilot Valves.
4-17, 4-21, 4-22, 4-23, 4-24, 4-25, 4-28, 5-1, 5-5, 5-19, 5-26 & Seal
202711.

KD60554-5 This kit is for use in repairing older Hydrant Valves with obsolete For 60554E and J Valves with
42846 Pilot Valve and contains 2-10, 2-12, 2-22, 3-3, 4-2, 4-4, 4-9, obsolete 42846 Pilot Valves.
4-17, 4-21, 4-22, 4-23, 4-24, 4-25, 4-28, 6-9, 6-10, 6-11,
Seal 600-015-10, MS29513-218, & Seal 202711.

KD60554-6 This kit is for use in repairing or converting 60554E or J Valves for Valves using this kit may have
use at temperatures down to -65° F and contains 2-22, 3-3, 4-2, limited operation life at normal
4-4, 4-9, 4-17, 4-21, 4-22, 4-23, 4-24, 4-25, 4-28, 6-10, 6-11, & operating temperatures and the
O-ring MS29513-014, Poppet 220424, Seal 220425, Seal 220426, & conversion may be only useful
Seal 220427. during the winter months.

KD60554-7 This kit is for use in repairing a complete 60554F or 60554U Valves
complete with Dual Air/Lanyard Pilot Valve and contains 2-10, 2-12,
2-22, 3-3, 4-2, 4-4, 4-9, 4-17, 4-21, 4-22, 4-23, 4-24, 4-25, 4-28, 6-3,
6-9, 6-10, 6-11, 6-13 & 6-15

KD640554-8 This kit is for use in converting any one piece upper housing (except
option S) to a two-piece aluminum/stainless steel upper. It contains
3-3, 3-4, 3-5 and 3-6.

KD60554-9 This kit is used to upgrade hydrant valves with serial numbers 8454 This kit provides the steel poppet
to 11160 to meet the requirements of the 3rd Edition of API 1584 – and the two piece upper housing
items 6A, required for older valves to meet
the requirements.

KD60554-10 This kit is used to upgrade later hydrant valves with the aluminum This kit is used to upgrade the
poppet assembly but with the appropriate upper half (aluminum poppet assembly only to the steel
housing with the replaceable stainless steel interface ring). Serial version to meet the requirements.
numbers 11161 and subsequent.

2KD42836 Kit to Upgrade the old style Lanyard Operated Pilot Valve, 42836, to
the newer production style, 44248, allowing the use of current
production hardware - items 5-1, 5-5, 5-16, 5-19, 5-20, 5-21, 5-22, 5-
23 & 5-26.

38
 SM60554 January 2011

Notes: 1. All part numbers beginning with "GF" are interchangeable with those beginning with either "AN" or "MS".
If the "GF" is followed by three numbers it is interchangeable with and "AN" part, otherwise it is
interchangeable with an "MS" part of the same number.
2. The recommended spare parts shown above are the number required to support 10 Units for one year or
each overhaul whichever is sooner. These quantities do not include replacement spares for intermediate
replacement of parts required by abuse or misuse of the equipment. The recommended quantities are
based on the ratio of spare parts sold for each unit during a one year period of time. The actual quantity
required will vary from location to location.
3. These items are not sold as separate parts, only the next assembly is available.
4. It is recommended that at least one each be on hand for each 50 or less hydrant valves in the system.
5. Air/Lanyard Pilots can be purchased without the Cage (7-2) or (8-2) and O-ring (7-11) or (8-11) if it is
desired to replace the unit as a complete pilot valve. The Cage (7-2) or (8-2) and O-ring (7-11) or (8-11)
can then be left installed inside the hydrant valve and need not be replaced. The part numbers for this
replacement pilot valve would be 47091-3 for Option F pilot valve without the M Option or 47051-4 with
the M Option. For Option U pilot valve without M Option it would be 47362-3 or with Option M it would be
47362-4.
6. The obsolete items 22-24 in Table 6 are no longer available as spare parts. If any one of the parts is
ordered it will automatically be replaced with 47370 Screw Assembly.
7. The obsolete item 2-11 is no longer available as a spare part. If it is ordered it will be replaced by
KD60554-10 to upgrade the poppet to the latest steel version.

39
Aerospace Group
Conveyance Systems Division
9650 Jeronimo Road
Irvine, CA 92618
Ph (949) 452-9500
Fax (949) 452-9992
www.eaton.com/aerospace