SM64349

April 2011
Applicable additional manuals:

Eaton
Aerospace Group
Conveyance Systems Division
Carter Brand
Ground Fueling Equipment

SM64019 2 Unisex Non-valved Coupling

SM64020 2 Unisex Valved Coupling
SM64031 3 Unisex Valved Coupling
SM44646 Hose End Regulator

UNDERWIN

SM349MISC Miscellaneous Adapter Assemblies

FBO OPERATIONS

SM40679 60427 Type QD Assemblies

SM61154 Dry Break Disconnect Assy
SM64015 Ball Valve

MODELS

64049

Carter now offers an underw

airfield, FBO, use with a new
for strainer checking, with
break. The underwing nozz
utilizes the Carter Unisex Co

SM64245 Low Pressure Drop Dry Break QD

Maintenance Manual

Pressure Fueling Nozzle

Model 64349

64049
Underwing Nozzle w
Unisex Coupling I
and Dust Caps for b

671 W. 17th St., Costa M

BACK

SM64349

April 2011

TABLE OF CONTENTS
PAGE

1.0

INTRODUCTION .................................................................................................................. 3

2.0

EQUIPMENT DESCRIPTION & OPERATION ..................................................................... 3

3.0

TABLE OF OPTIONS AND ORDERING INFORMATION.................................................... 4

4.0

SAFETY INFORMATION...................................................................................................... 6

5.0

SPECIAL TOOLS ................................................................................................................. 9

6.0

DISASSEMBLY..................................................................................................................... 9

7.0

INSPECTION ...................................................................................................................... 11

8.0

REASSEMBLY.................................................................................................................... 11

9.0

TEST................................................................................................................................... 12

10.0

ILLUSTRATED PARTS CATALOG .................................................................................... 14

FIGURE 1 - CHART OF OPTIONS AVAILABLE ........................................................................... 15

FIGURE 2 - CURRENT PRODUCTION CONFIGURATION......................................................... 17
FIGURE 3 - PREVIOUS CONFIGURATION ................................................................................. 19
FIGURE 4 -ADDITIONAL OPTIONS ............................................................................................. 21
FIGURE 5 - CONTINUITY CLIP INSTALLATION ......................................................................... 22
FIGURE 6 - POPPET-SHAFT RETENTION.................................................................................. 23
11.0

FAILURE MODES AND EFFECTS ANALYSIS.................................................................. 24

12.0

FAILURE MODES AND EFFECTS ANALYSIS HOSE END CONTROL VALVE ........... 29

SM64349

April 2011

Maintenance, Overhaul & Test Instructions

Eatons Carter Brand Model 64349
Pressure Fueling Nozzle
1.0

INTRODUCTION
and Marine Corps, 64349CDK, manual
SM64349CDK. These three manuals are more
specifically written to cover the special options
only and do not include all possible options as
this one does.

This manual furnishes detailed instructions

covering the maintenance and overhaul of
Eatons Carter brand Model 64349, Pressure
Fueling Nozzle and its various options.
There are specific manuals available for
nozzles that are qualified in accordance with
MIL-N-5877 and are designated D-1 and D-2
nozzles. These manuals are SM64349H and
SM64349J respectively. There is also a manual
for the special nozzle used by the U.S. Army

2.0

EQUIPMENT DESCRIPTION & OPERATION

2.1

DESCRIPTION

For the maintenance of options to the basic

64349 nozzle, refer to Options Table, Section
3.0. This table will reference the service
manual that should be used in the
maintenance of each option.

designed into the 64349 nozzle that must be

functioning to prevent an accident that would
result in spill of flammable liquids with the
consequential risk of fire, personal injury or
death, and property damage. Refer to Table
1.0 and Figures 1, 2 and 3 to identify individual
parts during the following discussion.

Model 64349H is a 2-1/2 inch pressure fueling

nozzle that has been qualified to MIL-N-5877,
Rev E and listed on that QPL as the D-1
nozzle. The 64349J is qualified to MIL-N-5877,
Rev E and listed on that QPL as the D-1
nozzle. The mil-spec does not allow for all of
the options shown in this manual but they can
be procured as noted herein. The unit is
designed to mate with adapters conforming to
MS24484 or equivalent. Models 64349H and J
supersede the previously qualified Models
61429H and 61429J respectively. The
difference between the nozzles is centered
around the collar-operated lever geometry and
the interlock pin shape. The new collar-lever
geometry improves operational safety, even
with aircraft adapters worn to the limits. The
change in the interlock pins improves collar
wear. In addition the 64349 Nozzles have
replaceable stick handles.

2.2.1.1 COLLAR LOCK AND INDEX PINS

Examination of the connection end of a
disengaged nozzle (nozzle not connected to
an adapter) discloses the three Collar Lock
Pins (19) and three Index Pins (21) installed
between the Collar (8) and the nozzle Seal
(43).
The three spring-loaded Collar Lock Pins (19)
engage three cutouts (arched shaped
windows) in the flange of the Collar (8) when
the Collar (8) is in the full dis-engaged position
and these Collar Lock Pins (19) prevent
accidental rotation of the Collar (8) of the
disengaged nozzle. Two of the three cutouts in
Collar (8) are normally elongated more than
the other one.

The basic nozzle would be procured under the

part number 64349 which includes the
standard stick handles and dust cap. Other
options that are available to build a nozzle to
specific specifications are listed in the table
shown in Section 3.0. The exploded views in
the figures at the end of the manual include
the various options available.

With the collar (8) locked in the disengaged

position, the flat portion of a ramp integral to
the Collar (8) is positioned over a flat on the
Lever (14) in a manner that prevents opening
the Poppet (15).

Older Model 61429 Nozzles can be converted

to the newer model by obtaining the
appropriate kit of parts. Refer to upgrade
manual UP64349.
2.2

OPERATIONS

2.2.1

SAFETY INTERLOCKS

The three Index Pins (21) mate with three slots

in a serviceable MS24484 Adapter Flange to
index the nozzle to the flange so the Collar (8)
mates with the flange lugs during engagement
and prevents disengagement of the Collar (8)
from the flange without releasing the three
spring-loaded Collar Lock Pins (19) to the
collar lock positions.

It is vital that each nozzle operator understand

that there are several safety interlock features
3

SM64349

2.2.1.1 LEVER/COLLAR INTERLOCK AND OVER

CENTER LINKAGE

STRONG WARNING!
The nozzle was not designed to be used with
the operating handle in a partially open
position as is the practice of some segments
of the services. The handle is not a flow
indicator and operating the nozzle in such
manner is strongly not recommended as
being a safe practice. If the interlock system
is worn the nozzle could be removed from
the aircraft in an open position causing a
spill.

Examination of the center portion of the Lever

(14) on a disengaged nozzle discloses the fact
that a portion of the edge of the Lever (14) is
beneath the flat portion of a ramp that is
integral to the Collar (8). With the Collar (8)
locked by the Collar Lock Pins (19), the Collar
(8) ramp prevents rotation of the Lever (14) to
the poppet open position. When the Collar (8)
is fully engaged to a serviceable MS24484
Adapter, the Collar (8) ramp clears the Lever
(14) and permits Lever (14) oration to the open
position. With the Lever (14) full open, the
round portion of the Lever (14) prevents rotation
of the Collar (8) in the disengage direction until
the Lever (14) has been fully closed. These
interlocks are designed to prevent accidental
opening of the poppet of a disengaged nozzle or
accidentally dis-engaging a nozzle with the
poppet open.

2.2.2.2

Do not leave the nozzle full of fuel and in a

completely closed off environment if the
temperature is rising. If stored on its hose
the hose will off-set some of the temperature
increase. A thermal relief system should be
employed if the nozzle is to be stored in such
a condition.
The nozzle is designed for operation up to and
including pressure of 180 psi. (Actually, the
nozzle will withstand and is tested to 300 psi
but the military specification has a burst
pressure rating of 180 psi. Burst pressure is
the pressure that the nozzle can withstand
without structural damage but need not be
operable after being subjected to that
pressure). Pressures caused by thermal
changes, thermal expansion can rise
dramatically. A temperature change of just 30
degrees in a closed nozzle can raise the
pressure within the unit to over 500 psi. The
30 degree temperature change can be from
10 to +20 F or any other change of this
magnitude. The temperature does not have to
be high at all to cause the pressure to
increase.

Thus, internal pressure against a closed

poppet, when the linkage is against the closed
mechanical stop, provides a force only in the
closed direction.
In a similar manner, with the lever in the full
open/mechanical stop position, the 50 lb. force
applied by the MS24484 Adapter Poppet
Spring provides a force only in the open
direction.
Refer to Service Bulletin SB3480801A for the
latest information on the Lever (14) as it
related to safety. Ask Eaton or your Eaton
Carter brand distributor for a copy if you do not
have one.
OPERATING INSTRUCTIONS

WARNING!

2.2.2.1 OPERATING NOTES AND WARNINGS

The use of unisex couplings with a valve or

any other valve on the inlet of the nozzle is not
recommended and is provided only at the
request of the customer. If used and the
nozzle/unisex coupling is removed from the
hose for storage, drain the nozzle of liquid
before storing.

The nozzle was designed to be operated in a

fully open position or to be closed. No middle
point is provided in the design.

3.0

THERMAL EXPANSION
WARNING!

The poppet operating internal linkage design is

such the linkage is over center at each
extreme of travel (lever full open against
internal mechanical stop or full closed against
internal mechan-ical stop).

2.2.2

April 2011

TABLE OF OPTIONS AND ORDERING INFORMATION

The following table should be used to determine the service manual to be used in the maintenance, repair or
replacement of parts designated by option letters to the basic 64349 nozzle.

SM64349

Notes:

April 2011

Option Letter

Part Number

Service Manual

A
B
C
D
E
F(2)
H
J
K
M
N
R
V
W
X
2
3H, 3P
5
6H, 6L, 6P
6Y, 6YH, 6YL, 6YP
7H, 7L, 7P
9
9H, 9L, 9P

44373-40 (1)
44373-60 (1)
44373-100 (1)
44311
41599
44646-(2)
44327
44326
44325
64031H
47566
44807-2
64019NV
47063
64019N
43045-1
64015
64020N
61154
64254
61154
44362
43108-1 thru 6

SM61154, SM64020, SM64031 or SM40679

SM61154, SM64020, SM64031 or SM40679
SM61154, SM64020, SM64031 or SM40679
SM64349
SM64349
SM44646
SM349MISC(3)
SM349MISC(3)
SM349MISC(3)
SM64032
SM349MISC
SM64349
SM64019
SM349MISC
SM64019
SM349MISC
SM64015
SM64020
SM61154
SM64254
SM61154
SM348MISC
SM40679

1.

Standard Screen shown, some options utilize 41767-**, 47115-** or 47307-100 in lieu of 44373-**. **
indicates that the mesh size must be added to get a complete part number, e.g. 44373-**.

2.

The part number shown is not complete and must include the spring setting (35, 45 or 55) to achieve a
complete number. The actual hose end regulator utilized will depend upon the inlet configuration chosen.
See Figure 1.

3.

Special manuals are available for 64349H, 64349J and 64349CDK on request.

4.

Safety clip (P/N 210641) for the 61154 dry break QD is considered FOD (Foreign Object Damage) and is
not included on military nozzle assemblies, however, it can be added as a no cost option.

The part number of a complete nozzle consists of four basic parts as illustrated below.
PART 1 Model number
64349
PART 4 Letter describing the inlet thread type &
size.
PART 3 Number describing the male adapter or ball valve required to
mate the desired inlet configuration.
PART 2 Options A-Y describing various changes to the basic nozzle configuration.

SM64349

April 2011

PART 2
The following options may be added as Part 2 of the part number as indicated above to order a unit to meet your
requirements:
OPTION
LETTER
*A
*B
*C
D
E
F3
F4
F5
H

OPTION
LETTER

DESCRIPTION
Adds 40-mesh Screen
Adds 60-mesh Screen
Adds 100-mesh Screen
Adds Bonding Cable
Adds Vacuum Breaker
Adds 35 psi Hose End Regulator
Adds 45 psi Hose End Regulator
Adds 55 psi Hose End Regulator
Adds 45 Elbow Inlet with Military Flange.

DESCRIPTION

J
K
M
N
R
V
W
X
Y

Adds Straight Inlet with Military Flange.

Adds QD with 2 Female Camlock Inlet.
Adds 3 Valved Unisex Coupling to Inlet.
Adds Universal (D-1/D/2) Inlet
Adds Circular Handle Grip.
Adds Green Unisex Coupling to Inlet.
Adds MIL-C-24356 Coupling to Inlet.
Adds Tan Unisex Coupling to Inlet.
Adds Military Bonding Cable (15)

Options A, B & C only available when a male half or a ball valve from Part 3 or Options V or X is specified.
Option A not available with Option 2 or 9.

PART 3
One of the numbers below must be included as Part 3, as indicated above, to specify the type of inlet configuration
desired. The nozzle may be ordered with the inlet terminating in an adapter half only if desired. In this case leave Part 4
blank. If a female half, either quick disconnect, ball valve or dry break of some configuration is desired, Part 4 must be
completed.
OPTION
LETTER
2

OPTION
LETTER
3

DESCRIPTION
Adds male half adapter to options H or J to
connect to 60427 type quick disconnect.

5
6Y
8

Adds Valved 2 Unisex Coupling

Adds male adapter half to mate 64254 Low

Pressure Drop Dry Break.
Adds male adapter half to mate 61154 Dry
Break when regulator is not used.

DESCRIPTION
Adds ball valve to options H or J. See
SM64015 for details concerning the operating
handles and defueling key.
Adds military male adapter half to mate 61154
dry break disconnect.
Adds male adapter half to mate 61154 Dry
Break when regulator is used.
Adds male adapter half to mate with 60427
style quick disconnect.

PART 4
One of the following letters must be included as Part 4 as indicated above to specify the inlet thread and size:
OPTION
LETTER
H
L

Inlet thread 2 NPT

Inlet thread 3 NPT

Example:

4.0

OPTION
LETTER

DESCRIPTION

P
*S

DESCRIPTION
Inlet thread 2 NPT
2 Female Camlock Inlet

64349H Standard D-1 Nozzle with 6-bolt inlet flange and 45 inlet flange.
64349J Standard D-3 Nozzle with 6-bolt straight inlet flange.
64349CF5H3DEH 64349 Nozzle with 55 psi regulator and ball valve with 100-mesh
strainer, drag ring and glass inspection lid with 2 NPT inlet

SAFETY INFORMATION

SM64349

Collar Assy (8) in the disengage direction until

the Lever (14) has been fully closed.

There are several safety interlock features

designed into the 64349 Nozzle that must be
functioning to prevent an accident that would
result in a spill of flammable liquids with the
consequential risk of fire, personal injury or
death, and property damage. Refer to Table 1.0
to identify individual parts during the following
discussion.
4.1

These interlocks are designed to prevent

accidental opening of the poppet of a
disengaged nozzle or accidentally
disengageing a nozzle with the poppet open.
The poppet operating internal linkage design is
such that the linkage is over center at each
extreme of travel (Lever (14) fully open against
internal mechani-cal stop or fully closed
against internal mechanical stop).

COLLAR ASSY LOCK AND INDEX PINS

Examination of the connection end of a
disengaged nozzle (nozzle not connected to
an adapter) discloses the three Collar Assy
Lock Pins (19) and three Index Pins (21)
installed between the Collar Assy (8) and the
Nozzle Seal (41). Refer to Figure 2. The
three spring-loaded Collar Assy (8) Lock Pins
(19) engage three cutouts (arched shaped
windows) in the interior flange of the Collar
Assy (8) when the Collar Assy (8) is in the fully
disengaged position. These Collar Assy Lock
Pins (19) prevent accidental rotation of the
Collar Assy of the disengaged nozzle. One of
the three cutouts in Collar Assy (8) is normally
narrower than the other two. This assures
that, even with badly worn adapters, a
minimum of two Lock Pins (19) will be
activated to prevent the nozzle from being
opened when not connected to an adapter.

Thus, internal pressure against a closed

poppet, when the linkage is against the closed
mechanical stop, provides a force only in the
closed direction.
In a similar manner, with the Lever (14) in the
fully open/mechanical stop position, the 50 lb.
force applied by the MS24484 Adapter Poppet
Spring provides a force to maintain the open
direction.
Refer to Service Bulletin SB3480801A for the
latest information on the Lever (14) as it
relates to safety. Ask Eaton or your Eaton
Carter brand distributor for a copy if you do not
have one.
4.3

With the Collar Assy (8) locked in the

disengaged position, the flat portion of a ramp
integral to the Collar Assy (8) is positioned over
a flat on the Lever (14) in a manner that
prevents opening the Poppet (15).

SAFETY INSPECTIONS
Note: The frequencies recommended for the
following inspections are our recommendations
based on nozzles that have been in daily
service for at least a year. The frequency that
is required will depend upon the degree of
maintenance extended to the equipment and
to the age of the equipment. It is not possible
for Eaton to recommend other than the safest
possible frequencies.

When connecting to an aircraft, the Index Pins

(21) mate with three slots in a serviceable
MS24484 Adapter Flange to index the nozzle
to the flange so the Collar Assy (8) mates with
the flange lugs during engagement and
prevents disengagement of the Collar Assy (8)
from the flange without releasing the three
spring loaded Collar Assy Lock Pins (19) to the
Collar Assy (8) lock positions.
4.2

April 2011

4.3.1

NOZZLE INSPECTIONS AT EACH

REFUELING OPERATION
The following inspections of the Nozzle are
recommended at each refueling operation:
A.
Inspect the connection end and verify
that the Index Pins (21) are intact, in place,
and not excessively worn or damaged. Verify
that all three Collar Lock Pins (19) are intact,
undamaged and are extended and engage
all three cutouts in the Collar Assy (8) and
physically prevent Collar Assy (8) rotation.

LEVER/COLLAR ASSY INTERLOCK AND

OVER CENTER LINKAGE
Examination of the center portion of the Lever
(14) on a disengaged nozzle discloses the fact
that a flat edge of the Lever (14) is beneath the
flat portion of a ramp that is integral to the Collar
Assy (8). With the Collar Assy (8) locked by the
Collar Assy Lock Pins (19), the Collar Assy (8)
ramp prevents rotation of the Lever (14) to the
poppet open position.

This inspection can be accomplished without

interruption of the normal operating procedure
and without adding appreciably to the operation
time by training the operator to automatically
observe the connection end of the nozzle upon
disconnection from the aircraft. If the Collar
Lock Pins (19) do not spring into their correct
position, it could mean that the aircraft adapter
is defective and should be inspected (see
paragraph 4.3.3) and reported as possibly being
defective. If the Collar Lock Pins (19) are not
extended and engaged in all three cutouts in the

When the Collar Assy (8) is fully engaged to a

serviceable MS24484 Adapter the Collar Assy
ramp clears the Lever (14) and permits Lever
(14) rotation to the open position.
With the Lever (14) fully open, the round
portion of the Lever (14) prevents rotation of the

SM64349

D.
Inspect the Lever (14) and the adjacent
ramp surface of the Collar Assy (8) and verify
that neither part is damaged or has missing
pieces that permit the Lever (14) to be rotated
to the open position with the nozzle disengaged
or that will allow the Collar Assy (8) to rotate to
the disengaged position when the Lever (14) is
open. Broken or missing parts can result in
dangerous fuel spills while refueling aircraft.

Collar Assy (8), the operator should squeeze the

Lever (14) and Handle Grip (4) together while
observing the connecting end of the nozzle.
This should cause the Collar Lock Pins (19) to
spring into the cutouts in the Collar Assy (8). If
not, then the nozzle should be taken out of
service.
B.
Prior to engagement to an aircraft inspect
the Lever (14) for cracks or looseness with the
Screw (39) that attaches it to the nozzle. Do not
use the nozzle if cracks or looseness is
apparent.

E.
Verify that the Lever (14) is in the fully
closed (against internal mechanical stop)
position. (This is necessary to assure that the
linkage is over center so internal pressure can
not force the poppet open during the Collar
Assy (8) engagement).

C.
Upon engagement to an aircraft and
opening the nozzle but before operating the
deadman control it is recommended that the
operator attempt to remove the nozzle from
the aircraft. This should not be possible. If it
can be removed, either the nozzle was never
fully engaged onto the aircraft or needs repair,
or the aircraft adapter, is in need of repair or
replacement.
4.3.2

April 2011

4.3.3

NOZZLE INSPECTION PRIOR TO EACH

OVERHAUL
Using Eaton S204451 three lug adapter flange
(or any standard flange that is a separate
loose part and not a part of some other
adapter housing) open the nozzle being careful
to drain all trapped fluid into a sump. Even if
the ball valve or a dry-break disconnect is
utilized, there will be a small quantity of
trapped fuel in the nozzle.

NOZZLES INSPECTIONS MONTHLY

BASIS
The following inspections of the nozzle are
recommended to be conducted on a monthly
basis as a minimum:

Check to see if there is a Cotter Pin (16)

installed through the slotted poppet and the
hole in the shaft. The pin must be installed in
the hole that is completely within the slotted
area of the poppet and the hole that allows for
proper poppet nose seal adjustment.

A.
Inspect the connection end and verify
that the three Index Pins (21) are intact and in
place. Verify that the three Collar Assy Lock
Pins (19) are intact and in place and extended
and engaging all three cutouts in the Collar
Assy (8) and physically preventing Collar Assy
(8) rotation. Check the Bearing Plate (42)
containing the pins for possible cracks.

Check the Poppet (15) to see what condition

the shroud is in. The shroud is a sheet metal
part that is press fitted onto the poppet and is
no longer considered necessary. If it is firmly
in place leave it until the next overhaul. If it is
loose remove it by disassembling the Cotter
Pin (16). Reassemble the unit less the shroud,
it is no longer needed. Using the poppet
adjustment tool 64000, adjust the poppet in
accordance with the appropriate instructions in
this service manual.

B.
Hold the nozzle with the outlet or
connecting end facing such that it can be
observed. Apply pressure on the Collar Assy
(8) in the direction to connect the nozzle
aircraft, counterclockwise, to take up the slack
and inspect the relative location of the three
Lock Pins (19) with respect to the cutouts in
the Collar Assy (8). The two Lock Pins (19)
that are engaged in the normally wider cutouts
should not be resting against the edge of their
respective cutouts. If there is a space between
these Index Pins (19) and the edge of the
normally larger cutout, the collar is still in
functional condition. If all three Lock Pins (19)
are resting against the edge of their respective
cutouts (there is no space), the Collar Assy (8)
may no longer be in a functional condition and
should be replaced if it fails the next step.

Grasp the poppet with one hand and holding

the nozzle with the other attempt to un-screw
the poppet from the shaft. The poppet will
move a slight amount taking up the slack
between the slot in the poppet, the hole in the
shaft and the cotter pin.
On newer nozzles (any received after January
2001 check that the wear ring on the inlet of
the nozzle is in place and is not worn out.
If all is correct close the nozzle and remove the
adapter flange. Put the nozzle back in service.
This procedure should be followed at each
overhaul of the unit.

C.
With the nozzle being held in the
position described above, attempt to open the
nozzle with the Lever (14). The nozzle should
be prevented from opening by the interference
between the Collar Assy (8) and the Lever
(14). If the nozzle is openable, it should be
removed from service and repaired.

4.3.4

AIRCRAFT ADAPTER INSPECTIONS

The following inspections of the aircraft
adapter are recommended to be carried out at

SM64349

B.
Visually check the three slots for
excessive wear. Excessive wear can permit
disengagement of a nozzle without release of
the three Collar Assy Lock Pins (19) and may
permit accidental poppet opening on the
disconnected nozzle. The use of Carter
Gauge 61657-2 will provide a no-go check for
the slots.

each refueling operation to assure that one is

connecting to a safe adapter:
A.
Visually check for bent, broken, missing
or excessively worn lugs or slots. Worn slots
are easily detected. A normal slot will have a
slight machine broken edge (chamfer of .030
inch (0.762 mm)). If the edge is worn such that
the corner is badly distorted and enlarged it
should be inspected more closely and
accurately. Carter Adapter Wear Gauge,
61657-2, should be utilized to check the width
and thickness of the lugs if they appear to be
worn. Wear of the thickness dimension of the
lug will promote premature nose seal leakage.
Wear of the width of the lug combines with slot
wear in defeating the nozzle interlock.
5.0

C.
If any of the above conditions are
observed, and or the gauge proves the
adapter to be defective, the refueling
operation should be continued only with
extreme caution. The nozzle, upon
disconnection, should be checked in
accordance with paragraph 4.3.1.A.

SPECIAL TOOLS

The following special tools are recommended for

proper repair and or overhaul of the nozzle:

S204451 Standard three lug bayonet

adapter flange or equivalent.

6958CG or 6958CH Adapter or

equivalent.
6.0

DISASSEMBLY

6.1

Remove nozzle from end of hose at quick

disconnect. Refer to appropriate service
manual depending upon type of swivel
disconnect utilized.

6.2

April 2011

61657-2 Adapter Wear Gauge

64000 Poppet Adjustment Gauge
61607 Ball (10 & 11) Assembly Tool
WL4680 Torque Wrench Kit

The above items are available from your Eaton

Carter brand distributor.

discard the screw and replace it with a new

one during reassembly. If Ball Assy Tool
61607 is available, screw it into the boss from
which Screw (23) was removed. Hold the
nozzle such that the Tool is below the nozzle
and rotate the Quick Disconnect Adapter (49,
50, 56, 59, or 64), Ball Valve (62) or Regulator
(47) until all Balls (11) have been captured in
the Tool. The correct amount of Balls (11) will
be captured when the level of Balls (11)
reaches the line scribed on the tube of the
Tool. If the Tool is not utilized, remove Balls
(11), 39 each, from Unit by hand. Hold bolt
hole vertical (pointed down) and allow all ball
bearings to fall through the bolt hole. Catch all
balls in a container. Some rotation between the
Body (9) and the attached Adapter, Ball Valve
or Regulator may be required to allow 39 Balls
(11) to fall out of hole. Remove the Adapter,
Ball Valve or Regulator (refer to appropriate
Service Manual). If Clip (12) is to be replaced,
use a pair of needle nose pliers to grasp the
existing part and pull it from the hole in the
Body (9). See Figure 5. Clear the hole of any
debris.

SM61154 .........Dry Break QD

SM64015 .........Ball Valve
SM349MISC ....Miscellaneous
Adapters/Universal Inlet
SM40679 .........60427 type QD
SM64019 .........Unisex Coupling
SM64020 .........Unisex Coupling
SM64031 .........Unisex Coupling
SM64254 .........Low DP DB QD
Screw (23) is a self-locking type screw that
utilizes a nylon insert in the threads to affect
the resistance required to provide the locking.
They are designed to be reused several times
before losing their locking effectivity. Note:
later version of the nozzle may incorporate a
Screw (23) that has a recessed Allen key head
instead of a screw driver slot. In addition the
O-ring (24) used on the newer Screw (23) is
smaller in diameter. It is important that the
correct O-ring (24) is used with the correct
Screw (23). The older Screw (23) [one with a
screwdriver head is larger in diameter and the
O-ring fits in the groove under the head of the
Screw (23), while the one with the Allen head
is smaller and the O-ring fits in a groove
machined in the threaded body of the Screw
(23)]. Using a torque wrench, remove Screw
(23) and O-ring (24) from lower half of Body
(9), measuring the torque during removal. If
the torque is less than 9.5 in lbs (0.11 m kg)

Remove O-ring (25) from internal groove in the

inlet of the Body (9). Visually inspect Wear
Ring (9A) installed in the internal groove for
excessive wear. If it appears to be worn
remove for further inspection in section 7.0.
6.3

To remove the Cover (1) it is necessary to

remove the appropriate Grips (4) or (6) or the
appropriate Handle (8A). If the Cover (1) is in
good condition it is not necessary to remove it
at this time. Leave it attached to the handle.

SM64349

The Screw (4B) should be removed with a

torque wrench and the removal torque
measured. This screw is a self-locking type
and is designed to be reused several times
before losing its locking capability. If the
torque is less than 6.5 in-lbs discard it and
replace it during reassembly.

6.12

Hold the nozzle outlet in an up position as

you would if the aircraft adapter were
underwing. View Lever (14) to determine the
age of the lever. Two older versions, both gray
in color, were produced, one with an operating
lever that is clocked in the 6 oclock position
when closed and the other with the handle
clocked in the 3 oclock position when closed.
The newer lever is black, clocked at 6 oclock
and is retained by a single screw through the
middle of the lever. Note: If a gray handle
retained by a single screw is present replace it
with a new black handle. Proceed to 6.12.1 if
the older handles are present, otherwise
proceed to 6.13.

6.12.1

If either older lever is present, hold the Body

(9) with the outlet in an upward position.
Rotate it until the two pipe Plugs (22) are
visible. Remove the left hand plug. If the
newer black lever is present move on to 6.13.

6.12.2

Remove Screws (35) through plug opening

using a torque wrench. The torque to remove
the Screws (35) shall not be less than 1.5 in.lbs. If it is less than that discard and replace
the Screws (35). Observe the orientation of the
Plate (36) with respect to the Lever (14) such
that it can be duplicated during reassembly.
Misorientation will result in not being able to
close the nozzle properly.

6.12.3

Remove Lever (14) from Body (9). Remove

Seal (37) and Backup Ring (38) from Lever
(14). Discard Seal (37) and Backup Ring (38).
For more information regarding the three
levers used on the nozzle see Service Bulletin
SB3480801A available from Carter or your
Carter distributor. Proceed to 6.15.

6.13

On nozzles with a black colored handle, serial

number 6520 and subsequent, the handle is
retained by a single screw located through the
center of the Lever (14). There is no need to
remove either of the Plugs (22) unless a leak
has been observed. Proceed to 6.14 if the
black handle is present.

6.14

Remove Screw (39), Washer (40) and O-ring

(41) from the center of the Lever (14). Discard
Screw (39) and O-ring (41). Pull Lever (14)
from Body (9). Remove Seal (37) and Backup
Ring (38) from Lever (14). Discard Seal (37)
and Backup Ring (38). Proceed to 6.15.

6.15

On nozzles with older handles proceed to

6.15.1. On nozzles with the newer handles
skip to 6.15.2.

6.15.1

Remove assembled Shaft (32), Pin (33), Link

(34) and Plate (36) with attaching parts from
Body (9). Remove Pin (33). Disassemble
Cotter Pin (29), Nut (30) and Crank Pin (31)
only if replacement is necessary. (Note that
older links will be red in color while the newer
ones will be natural stainless steel. Both are
accept-able for use.)

Remove the Bumper (5) only if replacement is

necessary by cutting through it.
6.4

Screw (7) is a self locking type screw that

utilizes a nylon insert in the threads to affect
the resistance required to provide the locking.
Self locking screws are designed to be reused
several times before losing their locking
effectivity. Note that here again, the older units
use the Screw (7) with a screwdriver slot and
newer units use one with an Allen head. These
Screws (7) are fully interchangeable. Using a
torque wrench, remove Screw (7) from Collar
Assy (8), measuring the torque during removal.
If the torque is less than 9.5 in lbs (0.11 m kg)
discard the screw and replace it with a new
one during reassembly. Remove the Balls (10)
from the bolt hole in the manner described in
paragraph 6.2 above. There are 49 balls in this
joint. The correct number of Balls (10) will be
removed when the level in the Tool reaches
the line created by the brass fitting that screws
into the Collar (8). If the Tool is not utilized,
store the Balls (10) in a separate container for
cleaning and replacement later.

6.5

Engage the nozzle to the S204451 flange (any

standard aircraft three-lug locking flange).

6.6

Remove Collar Assy (8) from Body (9) by

aligning the groove in the Collar Assy (8) with
detent on Body (9) and pull Body (9) from
Collar Assy.

6.7

Remove S204451 Adapter.

6.8

Turn Lever (14) to open Poppet (15).

6.9

Remove Cotter Pin (16) and unscrew the

Poppet Assy (15) from the Shaft (32). Older
nozzles had a flow diverting shroud present
that was pressed into place. If it is present and
firmly in place, leave it in place. If it is loose,
remove it completely and discard it. It is no
longer needed. Refer to Figure 6 for location
and identification of the shroud.

6.10

6.11

The Nozzle Seal Assembly (40) may be

removed by lifting off Body (9). The Plate (42)
may be removed from the Seal (41) by
spreading the ends of the Retaining Ring (43),
removing it from the groove in the Seal (41)
and then sliding the Plate (42) off the Seal
(41).
The three Lock Pins (19), three Lock Pin
Springs (20), three Index Pins (21) and O-ring
(18) may now be removed.

10

April 2011

SM64349

6.15.2

mounting screw is included with the new

replacement assembly.

Remove assembled Shaft (32), Pin (33), Link

(34) and Crank (36) with attaching parts from
Body (9). Disassemble Cotter Pin (29), Nut
(30), Crank Pin (29), Wave Washers (35) from
Link (34) and Crank (36). Discard Wave
Washers (35)

6.16

Do not remove Cable (44) or (66), option D or Y

only, unless replacement is required. The

7.0

INSPECTION

6.17

On newer nozzles with the wear ring in the

body, if worn remove for inspection. Measure
the smallest diameter and if less than 0.075
replace it.
Check the ball race located inside the Collar
Assy (8) for raised burrs in the same manner
as above.

Both holes in item 34 Link (.196 inch

(4.98 mm) diameter max. & .320 inch (8.13
mm) diameter max.).

Check the external ball race on the large OD of

the Body (9) in the same manner as above.

Bearing diameter of item 31 Pin (.300

inch (7.62 mm) diameter min).

Roll Pin (21) on a flat surface to check for

straightness. Replace any suspect pin.

Tapered bearing diameter of item 14

Leer (.697 inch (17.7 mm) diameter min on
large end & .635 inch (16.1 mm) diameter min
on small end).

Examine the Lever (14) for cracks. On newer

nozzles, also examine the fit between the
Lever (14) teeth and the Crank (36) teeth by
placing the two parts together and attempting
to rotate them against each other. The fit
should be snug and not loose. Replace both
parts if looseness appears to be present. Do
not replace only one part.

Measure diameter of the three round

holes in Plate (42). If holes are elongated or
exceed 0.222 inches (5.639 mm) the Plate (42)
should be replaced. Measure the width and
diameter of the other three holes. If the
diameter exceeds 0.330 (8.382 mm) or the
width across the flats exceeds 0.253 inches
(6.426 mm), the Plate (42) should be replaced.
REASSEMBLY

8.1

Reassemble in reverse order of disassembly

(Refer to Figure 2 or 3 depending upon the
version of nozzle), observing the following:

8.1.1

On option E remove the Vacuum Breaker (53)

only if replacement is required. The Vacuum
Breaker (53) is not economical to repair and
should be replaced, if needed, as a complete
assembly. Attempts to repair this unit may
result in fuel spills.

On older nozzles without a wear ring in the

body, check the ball race [internal groove that
mates the Balls (10)] inside the Body (9) for
raised burrs or buildup of material that may
prevent the disassembly of the mating
Adapter. The corner of the ball race should be
a smooth radius no greater than .03 inches
(.76 mm). The raised burr may be removed
with appropriate abrasive. If it is too large to
remove in this manner, replace the body.

It is recommended that all O-rings (18), (24),

(37) and (25), Back-up (38), Nose Seal (43),
Wave Washers (35) & Cotter Pins (16) & (29)
(if it is disassembled) be replaced upon every
overhaul. Note: Be sure to order the correct Oring (24) for the Screw (23) present. If a kit is
being used, it will contain both O-rings (24),
use the appropriate one and discard the other.
Inspect all metal parts for dings, gouges,
abrasions, etc. Use 320 grit paper to smooth
and remove sharp edges. Replace any part
with damage exceeding 15% of local wall
thickness. Use alodine 1200 to touch up bared
aluminum. Precisely measure the following
items. Replace any part that exceeds the
identified maximum or minimum wear limits:

8.0

April 2011

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

Make certain all components are clean and

free from oil, grease, or any other corrosion
resistant compound on all interior or exterior
surfaces. Wash all parts with cleaning
solvent and dry thoroughly with a clean, lintfree cloth or compressed air.

DO NOT use any form of grease on Balls (10)

or (11) and be certain to install proper number
of balls in each hole of Body (9) and collar
assembly. The use of Tool 61607 will facilitate
the counting and assembly of the Balls (10 or
11) back into the unit. Also make sure that Clip
(12) is installed properly to maintain continuity
11

SM64349

characteristic lugs of an adapter, the nose seal

may follow the poppet open and be difficult to
reinstall without disassembly. The Snap Ring
(43) will continue to be installed by the factory.

through the unit. Refer to Figure 5 for

installation information.
NOTE: A light coat of petroleum jelly can be
applied to all O-rings, springs, and screws for
ease of installation.

8.1.4

8.1.2
If Cotter (29) and Nut (30) were
removed during disassembly, torque Nut (30)
to 80 125 in lbs to align slots in nut with hole
in Crank Pin (31). When reinserting the subassembled parts noted in Para. 6.16 of the
disassembly procedure, through the inlet end
of the Body (9), ensure that the Shaft (32) is
inserted into the Bodys (9) axial guide bore far
enough that the bore contains the Dowel Pin
(33).

Use Poppet Adjustment Gauge, 64000, to

facilitate the adjustment of the Poppet (15) onto
the Shaft (32). Follow instructions furnished with
the gauge. If the gauge is not used, place a
straight edge across the center of the elastomer
lip of the Seal (41). Use feeler gages to measure
the average dimension between the bottom of
the straight edge and the Poppet (15) face. This
dimension should be .070 to .110 inch (1.8 to 2.8
mm). If it is not, calculate the required poppet
dimension as follows: (one quarter (1/4) turn of
the Poppet (15) axially displaces the Poppet (15)
face about .020 inch (0.51 mm).
A.
If the feeler gage measurement is too
long, prepare to unscrew (loosen) the Poppet
(15) one quarter (1/4) turn for each .020 (0.51
mm) inch of required adjustment.

Reinstall the Plug (22). NOTE: Plug (22) when

purchased from Carter includes a sealant and
the use of Teflon tape is not required. If new
Teflon tape is used on reinstallation do not
utilize more than 1 wraps of tape. Excessive
use of tape could lead to the cracking of the
Body (9).

B.
If the measurement is too short,
prepare to tighten the Poppet (15) one quarter
(1/4) turn for each .020 (0.51 mm) inch of
required adjustment.

On nozzles with the newer levers the

orientation of the Crank (36) is not critical at
this point since it will be aligned with the Lever
(14). Install Backup Ring (37) and O-ring (38)
onto Lever (14) and insert into Body (9). Lever
(14) should be aligned with Crank (36) to result
in the Lever (14) being at the 9 oclock position
when in the closed position (3 oclock when
opened). The teeth in both parts should
mesh during the assembly. Place Washer
(40), O-ring (41) onto Screw (39) and insert
into hole in center of Lever (14). Torque the
Screw (39) in the outer portion of the Lever
(14) to 125 5 inch pounds, loosen the Screw
(39) and retorque to 125 5 inch pounds.
Should it be desired to be able to change the
nose seal of the nozzle without a major
disassembly of the unit it is possible to do so
by eliminating Snap Ring (43). One word of
caution should this be done. If the nozzle is
opened with a tool that does not have the

9.0

TEST

9.1

The following test procedures will be

accomplished after overhaul:

Connect nozzle to S204451 flange when

installing the Poppet (15). Use the Lever (14)
and move the Shaft (32) to its fully extended
(open) position to install the Poppet Assy (15).
Before inserting the Cotter (26), adjust the
Poppet Assy (15) using the following
instructions:

On nozzles with the older levers (Figure 3),

assure that the orientation of the Plate (36) to
the Lever (14) is as observed prior to
disassembly. Wave Washers (42) are not
used on these nozzles with Plate (36). Use
the 9/64 inch Allen wrench through the Bodys
(9) pipe thread port to secure the Plate (36) to
the end of the Lever (14) shaft with the four
socket head Screws (35). Torque each of the
Screws (35) to 16 to 18 inch pounds above the
torque required to rotate the screws in the
thread locking inserts installed in the Lever
(14) end.

8.1.3

April 2011

12

8.15

Once the proper Poppet Assy (15) adjustment

is made, rotate the Poppet toward the
tightening direction until the next slot in the
Poppet Assy (15) is in line with the hole in the
Shaft (32). Insert the Cotter (26) and bend
over the ends to retain in place in accordance
with Figure 6. Note it is important that the
correct length of Cotter Pin (16) is utilized for
the assembly.

8.2

If the Grip (4) or (6) requires replacing due to

wear or the replacement of the Cover (1), the
new Grips (4) or (6) shall be reinstalled.

8.3

If Bumper (5) is to be replaced onto Collar

Assy (8) warm Bumper (5) in water at 160180 F to soften before pressing onto Collar
Assy (8) .

8.4

If stick Handles (8A) were removed for

replacement they should be reassembled to
Collar (8) using the appropriate Screws (8B),
Washers (8C) and Nuts (8D). Tighten to
secure Handles (8A) into place in the Collar
(8).

9.2

Test conditions

SM64349

Test media shall JP-4, Jet A or odorless

kerosene, commercial solvent 140.
9.3

Functional Test

9.3.1

The nozzle shall be inserted and locked into a

test adapter, Carter 6958CG or CH or equivalent
and the nozzle valve actuated by use of the
crank Lever (14) from the fully closed to fully
open position a minimum of five times. There
shall be no evidence of binding or excessive
force required for valve actuation.

9.4

Leakage Test

9.4.1

With the nozzle outlet in the normal open

position, and the test adapter outlet closed,
pressurize the inlet to five PSIG and hold for
one minute minimum. There shall be no
evidence of external leakage from the nozzle.

9.4.2

Repeat the leakage test at 60 PSIG and 120

PSIG.

9.4.3

Close and disengage the nozzle and repeat

9.4.1 and 9.4.2.

13

April 2011

SM64349

10.0

April 2011

ILLUSTRATED PARTS CATALOG

Table 1.0 tabulates the parts and sub-assemblies comprising the 64349 Pressure Fueling Nozzle. The item
numbers of the table are keyed to the exploded views of the nozzle diagrammed in Figures 1 thru 6.
TABLE 1
OPTIONS
Fig.
No.

Item

Part
Number

Description

Used as Option

1,4

46

44311

Cable Assy ..................................................................

47
48
49
50
51A
51B
51C
51D
52
53
54
55
56
57
58
59
60

44646-*
44326
44327
44663
44373-**
41767-**
47115-**
47307-100
43045-1
43108-*
44325
41599
47063
64349
44697
44701
61154H
61154L
61154P
64019N
64015*
64019NV
44362
44771
47028
64031H
64020N
47566
47633
47584-1
47854-2
47584-3
210641

Hose End Control Valve (Note 1) ................................

D-2 Flanged Inlet (Note 4)...........................................
D-1 Flanged Inlet (Note 4)...........................................
Adapter 61154 (Note 7)............................................
Screen Assy (Note 6) ..................................................
Screen Assy (Note 6) ..................................................
Screen Assy (Note 6) ..................................................
Screen Assy (Note 6) ..................................................
Adapter Option 2 (Note 4) ........................................
QD, Female Half (Note 3) ...........................................
QD, 2 Female Camlock (Note 4)................................
Vacuum Breaker .........................................................
MIL-C-24356 Inlet (Note 4)..........................................
Nozzle .........................................................................
Short Male Adapter Assy (Note 2)...............................
Long Male Adapter Assy (Note 2) ...............................
Dry Break Assy, 2 NPT (Note 7) ..............................
Dry Break Assy, 3 NPT (Note 7) .................................
Dry Break Assy, 2 NPT (Note 7) .................................
2 Unisex coupling (Note 13).......................................
Ball Valve (Note 9) ......................................................
2 Unisex coupling (Green) (Note 13).........................
Male Adapter Assy (Note 4) ........................................
Female Half Inlet Assy (2: Camlock) ..........................
Military Style Bonding Cable .......................................
3 Unisex Coupling (Tan) (Note 14) ............................
2 Valved Unisex Coupling (Tan) (Note 13).................
Universal Inlet - D-1/D-2..............................................
Military Male Half Assembly Low DP DB (Note 8)..
Female Half Assembly Low DP DB 2 NPT..
Female Half Assembly Low DP DB 2 1/2 NPT ....
Female Half Assembly Low DP DB 3 NPT........
Safety Ring..................................................................

F3, F4, F5
J
H
6
A, B, C
B,C
A, B, C
C
2
9H, L, P
K
E
W
All
7
8
7H
7L
7P
X
3H, 3K, 3L, 3N,3 P
V
9
S
Y
M
5
N
6Y
6P
6H
6L

61
62
63
64
65
66
67
68
69
70
71
72
73
74***

6YPX, 6YHX, 6YLX

*** Safety Clip (P/N 210641) for the 61154 Drybreak QD is considered FOD (Foreign Object Damage) and
not included on military nozzle assemblies; however, it can be added as a no cost option.

14

SM64349

April 2011

***

*** Item 74 Safety Clip (P/N 210641) for the 61154 Drybreak QD is considered FOD (Foreign Object Damage) and not
included on military nozzle assemblies; however, it can be added as a no cost option.

FIGURE 1
CHART OF OPTIONS AVAILABLE

15

SM64349

April 2011

TABLE 2.0
Current Production Version
Fig.
No.

1, 4
2

Item

Part Number

1
2-3
4
4A
4B
5
6
7
8
8A
8B
8C
8D
9

207799
Cover.......................................................
Left intentionally blank
207808
Grip .........................................................
GF960-516
Washer....................................................
GF16997-78L
Cap Screw ..............................................
23622
Bumper ...................................................
207816
Circular Handle .......................................
220484
Screw, Pan Head (Note 10)....................
220269
Collar.......................................................
210600
Handle ....................................................
GF4-13A
Screw ......................................................
GF960-416
Washer....................................................
GF21042-4
Nut ..........................................................
207784
Body (Replaced by 47375).................................
47375
Body Assembly (on newer nozzles) ................
221341
Body (not available as a spare part - order
47375 only) ...........................................
220893
Wear Ring (newer nozzles) (Note 8) ...........
221075
Bearing, Ball ...........................................
221075
Bearing, Ball ...........................................
209853
Clip..........................................................
Left intentionally blank
220878-1
On/Off Act. Lever (New Lever) (Note 11)............
210593
Poppet.....................................................
GF24665-302
Pin, Cotter...............................................
Left intentionally blank
M25988/1-145
O-ring ......................................................
220272
Pin, Collar Lock.......................................
20909
Spring, Collar Lock Pin ...........................
24780
Pin, Indexing ...........................................
210388
Plug.........................................................
220484
Screw, Pan Head....................................
MS29512-03
O-ring (Note 10).....................................
M25988/1-235
O-ring ......................................................
Left intentionally blank
GF24665-1013
Pin, Cotter...............................................
GF320C4
Nut, Castellated ......................................
220886
Pin, Crank (Note 11) ...............................
210368
Shaft .......................................................
D9-437
Dowel Pin................................................
207795
Link .........................................................
5806-21-3
Wave Washer (Note 11) .........................
220878-3
Crank (Note 11) ......................................
207792
O-ring, TFE Coated ................................
MS28774-017
Back-up...................................................
GF16997-69
Screw (Note 11)......................................
5710-54-60
Washer (Note 11) ...................................
MS29513-010
O-ring (Note 11).........................................
47058
Nose, Seal Assy ........................................
209029
Seal, Nozzle .........................................
220271
Plate, Bearing.......................................
24636
Ring, Snap............................................

9A
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26-28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
44
45

Description

16

Units/
Assy

Nozzle
Option

All

5340-01-246-2706

2
2
2
1
1
1
1
2
2
2
2
1
1

All but U
All
All
All
U
All
All
All
All
All
All
All
All

5340-01-324-0954
5310-00-167-0820
5305-01-189-3761
4930-00-848-1310

1
1
49
39
1

All
All
All
All
All

1
1
1

All
All
All

1
3
3
3
2
1
1
1

All
All
All
All
All
All
All
All

5330-01-010-2419
5315-01-385-5535
5360-00-155-5099
4930-01-053-0194
4730-01-198-9551
5305-01-246-3868

1
1
1
1
1
1
2
1
1
1
1
1
1
1
1
1
1

All
All
All
All
All
All
All
All
All
All
All
All
All
All
All
All
All

5315-01-025-4510
5310-00-721-4434

NSN

5305-01-246-3868
4930-01-385-9453
5340-01-415-1292

Use 47375

3110-01-247-1056
3110-01-247-1056

4820-01-252-3725
5315-00-234-1864

5330-01-007-4899

3040-01-385-8986
5315-01-341-8766

5330-01-246-7351
5330-00-833-4210

4930-01-385-9488
5330-01-264-0134
3110-01-385-3438
5340-01-053-0192

SM64349

FIGURE 2
CURRENT PRODUCTION CONFIGURATION

17

April 2011

SM64349

April 2011

Table 3
Previous Configuration Nozzle
Fig.
No.

1, 4
3

Units/
Assy

Item

Part Number

3
4
4B
4A
5
6
7

Left intentionally blank

207808
Grip ........................................................
GF16997-78L
Cap Screw .............................................
GF960-416
Washer ..................................................
23622
Bumper ..................................................
207816
Circular Handle......................................
220484
Screw, Pan Head (Note 10)...................
209827
Screw, Cap (Note 10) ...........................
220269
Collar .....................................................
210600
Handle ...................................................
GF4-13A
Screw .....................................................
GF960-416
Washer ..................................................
GF21042-4
Nut .........................................................
207784
Body (Replaced by 47375) ....................
47375
Body Assembly (on newer nozzles) .........
221341
Body (not available as a spare
part - order 47375 only)....................
220893
Wear Ring (newer nozzles) (Note
8) ...........................................................
221075
Bearing, Ball ..........................................
221075
Bearing, Ball ..........................................
209853
Clip.........................................................
Left intentionally blank
220270
On/Off Act. Lever (Old Lever) (Note 11)...
220561
On/Off Act. Lever (Old Lever) (Note 11) .....
210593
Poppet ...................................................
GF24665-302
Pin, Cotter..............................................
Left intentionally blank
M25988/1-145
O-ring ...................................................
220272
Pin, Collar Lock....................................
20909
Spring, Collar Lock Pin ........................
24780
Pin, Indexing ........................................
210388
Plug......................................................
220484
Screw, Pan Head.................................
209827
Screw, Cap (Note 10) .........................
MS29512-03
O-ring (Note 10)..................................
MS29513-013
O-ring (Note10)...................................
M25988/1-235
O-ring ...................................................
Left intentionally blank
GF24665-1013
Pin, Cotter ............................................
GF320C4
Nut, Castellated ...................................
207788
Pin (Note 11)........................................
210368
Shaft ....................................................
D9-437
Dowel Pin.............................................
207795
Link ......................................................
LP65U82J12M
Screw ...................................................
GF16995-28
Screw (Note 11)....................................
207792
O-ring, TFE Coated ..............................
MS28774-017
Back-up.................................................
47058
Nose, Seal Assy ...................................
209029
Seal, Nozzle ....................................
220271
Plate, Bearing..................................
24636
Ring, Snap ......................................

8
8A
8B
8C
8D
9

9A
10
11
12
13
14A
14B
15
16
17
18
19
20
21
22
23
24
25
26-28
29
30
31
32
33
34
36
37
38
42
43
44
45

Description

18

Nozzle Option
NSN

2
2
2
1
1
1
1
1
2
2
2
2
1
1

All but U
All
All
All
U
All later units
All older units
All
All
All
All
All
All
All

5340-01-324-0954
5310-00-167-0820
5305-01-189-3761
4930-00-848-1310

1
1

All
All

49
39
1

All
All
All

3110-01-247-1056
3110-01-247-1056

1
1
1
1

All older units

All newer units
All
All

3040-01-385-9064

1
3
3
3
2
1
1
1
1
1

All
All
All
All
All
All newer units
All older units
All newer units
All older units
All

5330-01-010-2419
5315-01-385-5535
5360-00-155-5099
4930-01-053-0194
4730-01-198-9551
5305-01-246-3868

1
1
1
1
1
1
4
4
1
1
1
1
1
1

All
5315-01-025-4510
All
5310-00-721-4434
All
All
3040-01-385-8986
All
5315-01-341-8766
All
All newer units
5305-01-413-0746
All older units
All
5330-01-246-7351
All
5330-00-833-4210
All
4930-01-385-9488
All
5330-01-264-0134
All
3110-01-385-3438
All
5340-01-053-0192

5305-01-246-3868
4930-01-385-9453
5340-01-415-1292

4930-01-244-8043

4820-01-252-3725
5315-00-234-1864

5330-00-248-3828
5330-01-007-4899

SM64349

April 2011

FIGURE 3
PREVIOUS CONFIGURATION
Note:

1.
Previous configuration nozzles can be updated to the current production configuration by
using KD64349-12 Kit on overhaul.

19

SM64349

April 2011

Table 4
Repair Kit Information
Kit Part
Number

Description

Kit Contents

NSN

KD64349-1

Kit Maintenance Soft goods for normal

overhaul of basic 64349

Items 7, 12, 16, 18, 23, 24, 25,

29, 37, 38, 39, 41, 43,
M25988/1-040 O-ring,
M25988/1-235 O-ring &
207807 Seal

4930-01-385-9025
(Note 12)

KD64349-2

Kit to make a major overhaul when used

with a 1 kit.

Items 1, 4, 5, 14, 15, 19, 20,

21, 31, 35, 36, 39, 40 & 41

4930-01-385-9083
(Note 12)

KD64348-12

Converts one-piece lever to

two-piece design.

Items 14, 24, 29, 31, 35 and

36-41.

(Note 12)

KD64201-3

Kit to overhaul the 64254 Dry Break.

Notes:
1.
2.
3.
4.
5.

6.
7.
8.
9.
10.

11.

12.
13.
14.

Refer to SM44646, as appropriate, for detail information. *Add pressure rating to part number to
complete it.
Refer to SM61154, SM40679, SM64254 or SM64015 for detail information.
Refer to SM40679 for detail information.
Refer to SM349MISC for detail information.
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.
Refer to SM44315, SM61154, SM40679, SM64015 or SM64020 for detail information. **Add screen
mesh size to part number to complete it. Only 100-mesh screen available on Option M.
Refer to SM61154 or SM64001 for detail information.
Item 9A is not present on older nozzles.
Refer to SM64015 for detail information.
The MS29512-03 Gasket (24) is used with Screw (23) 220484. This is available as an assembly (and is
more economical to order as such) as part number KDT-1191. If Screw (23) 209827 is to be replaced
do so with KDT-1191. O-ring (24) MS29513-013 is used with the older Screw (23) 209827 only.
There have been three item 14 On/Off Actuating Levers used on the 64349 Nozzle. Item 14, replaces
the previously used items 14A and 14B. Several other parts are needed to replace (14A) or (14B) and
are furnished with KD64349-2 and KD6434812. Neither (14A) or (14B) are available, they will
automatically be replaced by KD64349-12. Wave Washer (35) is used to provide friction in the lever
mechanism to keep the lever in the open position during flow conditions.
Contents of these kits have changed in the past year hence kits in the stock system may be different
than the contents listed.
Refer to SM64019 for detail information.
Refer to SM64031 for detail information.

20

SM64349

FIGURE 4
ADDITIONAL OPTIONS

21

April 2011

SM64349

FIGURE 5
CONTINUITY CLIP INSTALLATION

22

April 2011

SM64349

FIGURE 6
POPPET-SHAFT RETENTION

23

April 2011

SM64349

11.0

FAILURE MODES AND EFFECTS ANALYSIS

11.1

Notes that apply to this analysis:

A.

April 2011

Hazard category, hazard probability, and real hazard index (RHI) are defined herein.

B.
Visual inspection means examining the nozzle for obvious cracks, damage, and broken lugs, prior to initial
pressurization.
C.
Pressure test prior to use means pressurizing the nozzle and attached hose to operating fuel pressure, then removing
pressure, prior to aircraft arrival.
D.
Shut off fuel at source will be the first action for any leak. To further improve operating safety, this procedure should be
used for all refueling operations. In addition, fuel flow should be turned on at the source, not at the nozzle.
E.
11.2

Item numbers referred to in this section are those used in Figure 5.

RISK ASSESSMENT - A risk assessment procedure based upon the hazard probability, as well as hazard severity may be
required to establish priorities for corrective action and resolution of identified hazards. One example is the real hazard index; a
numeric rank ordering of a mathematical combination arrived at by assigning numerical values to the severity category and
probability level.
A.
Hazard Probability - The probability that a hazard will occur during the planned life expectancy of the system can be
described in potential occurrences per unit of time, event, population, item or activity. Assigning a quantitative hazard is generally
not possible early in the design process. A qualitative hazard probability may be derived from research, and evaluation of historical
safety data from similar systems.
Level

Descriptive word

Specific Individual Item

Fleet or Inventory

A (6)

Frequent

Likely to occur frequently

Continuously experienced

B (5)

Reasonably probable

Will occur several times in life of an item

Will occur frequently

C (4)

Occasional

Likely to occur sometimes in the life of an item

Will occur several times

D (3)

Remote

So unlikely, it can be assumed that this hazard

will not be experienced

Unlikely to occur but possible

E (2)

Extremely Improbable

Probability of occurrence cannot be

distinguished from zero

So unlikely it can be assumed that this

hazard will not be experienced

F (1)

Impossible

Physically impossible to occur

Physically impossible

B.
Hazard Severity - Hazard severity categories are defined to provide a qualitative measure of the worst potential consequences
resulting from personnel error, environmental conditions, design inadequacies, procedural deficiencies, or system, subsystem or component
failure/ malfunction.
Severity Category

C.

Descriptive word

Results

(4)

Catastrophic

May cause death or system loss

II

(3)

Critical

May cause severe injury, or system damage

III

(2)

Marginal

May cause minor injury, minor occupational illness, or minor system

damage

IV

(1)

Negligible

Will not result in injury, occupational illness, or system damage

Real Hazard Index (RHI) Matrix - (RHI = Hazard Severity X Probability Level)
HAZARD SEVERITY

PROBABILITY
LEVEL

A
B
C
D
E
F

(6)
(5)
(4)
(3)
(2)
(1)

I
(4)
24
20
16
12
8
4

General guidelines for required action.

RHI

24

II (3)
18
15
12
9
6
3

III (2)
12
10
8
6
4
2

IV (1)
6
5
4
3
2
1

SM64349

11.3

1-8

No action required.

9-12

Special precautions required, investigate redesign.

13-24

Hazardous, redesign necessary or procedural control if redesign is impractical.

FAILURE MODES AND EFFECTS ANALYSIS (FMEA) Refer to Figure 5 for component numbers mentioned in column one.

NR

COMPONENT

FUNCTION

FAILURE
MODE

Bumper Ring
(7)

Protects lug ring on

collar

Missing or
torn

Possible ring damage

Collar (10)

Secures nozzle to
aircraft receptacle

Cracked or
Broken

April 2011

Collar
retaining
balls (49)

Retaining
ball screw (9)

Retain nozzle
collar to nozzle
body

Provides access
for collar retaining
balls. Allows balls
to move freely in
raceway.

RESULT OF FAIL

HAZARD
CATEGORY

HAZARD
PROBABILITY

REAL
HAZARD
INDEX
(RHI)

CORRECTIVE
ACTION

IV

(1)

4 (C)

Visual Inspection

Difficulty in connecting to
aircraft

IV

(1)

3 (D)

Damaged
Ball Grooves

Difficulty in connecting to
aircraft

IV

(1)

3 (D)

Cracked,
worn or bent
lugs

Improper seal resulting in fuel

leak

II

(3)

4 (C)

12

Visual Inspection

Broken or
missing lug
(s)

Nozzle released from aircraft

receptacle resulting in fuel
spill/spray

(4)

3 (D)

12

Visual Inspection

Broken or
galled

Difficulty in connecting to
aircraft

IV

(1)

4 (C)

(no hazard)

Missing (all)

Unit unusable

IV

(1)

4 (C)

Visual Inspection

Missing (3548)

Unit may not align; difficulty

connecting to aircraft.
Possible fuel leak.

II

(3)

4 (C)

12

1) Pressure test
prior to use

Missing (34
or less)

No effect

IV

Missing

Loss of retaining balls

Loose

Possible loss of retaining

balls

2) Visual
Inspection
(1)

4 (C)

II (3) or IV
(1)

4 (C)

12 or 4

Depends on
number of balls
missing (see item
#3)

II (3) or IV
(1)

3 (D)

9 or 3

Same as above,
but less likely

Handle grip
(2)

Provides gripping
surface for handle

Missing or
torn

None

IV

(1)

4 (C)

Handle Bolt
(2)

Holds handle grip

in place

Missing or
loose

Handle separates

IV

(1)

4 (C)

Handle Nut
(2)

Holds handle grip

in place

Missing or
loose

Handle separates

IV

(1)

4 (C)

Body

Holds all
components
together

Cracked

1) Fuel leak

(4)

3 (D)

12

1) Pressure test
prior to use

2) Difficulty in attaching to
aircraft

IV

(1)

3 (D)

2) Visual
Inspection
Same as above

Access Port
Plug (2)

Provides access
for applying
pressure gauge or
other accessories

Missing

Massive fuel spill

(4)

3 (D)

12

10

Handle

Rotates collar to
attach or detach
nozzle

Missing, bent
or broken

Cannot attach nozzle

IV

(1)

3 (D)

11

Poppet Valve
seal holder

Retains poppet
valve seal

Missing or
broken

Fuel spray

(4)

3 (D)

12

12

Snap Ring

Holds flange onto

poppet valve seal
holder

Missing or
broken

Poppet seal does not stay

completely in place; minor
fuel leak

II

(3)

2 (E)

Poppet valve may be blocked

from closing

II

(3)

2 (E)

25

Use another
handle

Pressure test
prior to use

Shutoff fuel at
source.. Aircraft
poppet valve will
prevent backflow

SM64349

NR

COMPONENT

FUNCTION

13

Body O-Ring

Provides seal
between body and
valve seat
assembly

14

Seal Flange

Attaches poppet
valve seal to
nozzle body

April 2011

HAZARD
PROBABILITY

REAL
HAZARD
INDEX
(RHI)

(4)

3 (D)

12

Pressure test
prior to use

II

(3)

3 (D)

Same as above

Fuel Spray

(4)

3 (D)

12

Same as above

Bent or
warped

Improper poppet valve seal

resulting in fuel spray

(4)

3 (D)

12

Same as above
Same as above

HAZARD
CATEGORY

FAILURE
MODE

RESULT OF FAIL

Missing

Fuel Spray

Torn or
broken

Fuel leak

Cracked or
loose

CORRECTIVE
ACTION

15

Poppet Valve
Seal

Seals poppet valve

in body

Torn or
broken

Fuel Spray

(4)

3 (D)

12

16

Alignment
Pin (3)

Provides proper
alignment between
nozzle and aircraft
receptacle

Missing 1 or
2

None

IV

(1)

3 (E)

Missing all 3

Difficulty attaching nozzle to

aircraft

IV

(1)

3 (E)

Missing 1 or
2

None

IV

(1)

3 (E)

Stuck
retracted (1
or 2)

None

IV

(1)

3 (E)

Missing all 3

Loss of nozzle collar

interlock. Can flow fuel
without nozzle attached to
aircraft

(4)

3 (D)

12

Procedural error
also needed for
fuel spill. Valve
link has
overcenter
feature to prevent
fuel pressure from
opening valve

Stuck
retracted (All
3)

Same

(4)

3 (D)

12

Same as above

Stuck
extended

Cannot attach nozzle to

aircraft

IV

(1)

3 (E)

Installed
backwards or
upside down

Cannot assemble nozzle

IV

(1)

3 (E)

Missing or
broken (1 or
2)

None

IV

(1)

3 (E)

Missing or
broken (All 3)

Loss of collar interlock

(depending on orientation of
aircraft receptacle)

(4)

3 (D)

12

Same as above

Pre-use visual
inspection

17

18

Collar Lock
Pin (3)

Collar Lock
Pin Spring
(3)

Prevents rotation of
nozzle collar

Keeps collar lock

pin extended

Can flow fuel without nozzle

attached to aircraft
19

Swivel Inlet
Tube

Attaches refueling
hose to nozzle

Cracked or
broken

Fuel spray or leak

(4)

3 (D)

12

20

Swivel
Bearing

Keeps swivel inlet

tube properly
aligned

Missing or
broken

Difficulty in attaching nozzle

to aircraft

IV

(1)

3 (E)

21

Retaining
Balls (39)

Keeps swivel inlet

tube attached to
nozzle

Broken or
galled

Difficulty in attaching nozzle

to aircraft

IV

(1)

3 (E)

Missing (All)

Unit unusable; swivel tube

wont stay attached

IV

(1)

3 (E)

Missing (2533)

Fuel leak

II

(3)

4 (C)

12

Missing (24
or Less)

None

IV

(1)

4 (C)

Missing

Loss of retaining balls

II

(3)

4 (C)

12

IV

(1)

22

Retaining
Ball Screw

Provides access
for swivel retaining
balls. Allows balls
to move freely in
raceway

26

Pressure test
prior to use

Depends on
number of balls
missing (See item
#21)

SM64349

NR

COMPONENT

FUNCTION

FAILURE
MODE
Loose

RESULT OF FAIL

April 2011

HAZARD
CATEGORY

Possible loss of retaining

balls

II

(3)

IV

(1)

HAZARD
PROBABILITY
3 (D)

REAL
HAZARD
INDEX
(RHI)
9
3

23

Retaining
Ball Screw
O-Ring

Provides sealing
surface for
retaining ball plug

Missing or
broken

None

IV

(1)

4 (C)

24

Poppet Valve

Shuts off fuel flow

Fails open

Fuel flow cant be shutoff

(4)

3 (D)

12

CORRECTIVE
ACTION
Same as above
but less likely

1) Pressure test
prior to use
2) Shut off fuel at
source

25

26

27

28

29

30

Valve Shaft

Valve Cotter
Pin

Valve Link

Valve Link
Pin

Crank Plate

Valve Link
Bolt

Connects poppet to
handle assembly
(In-Line with valve
link)

Prevents poppet
valve from turning
(and loosening
from shaft)

Connects Poppet
Valve to crank
assembly (in line
with valve shaft).

Connects valve
shaft to valve link

Attaches valve
assembly to crank
handle

Fastens valve link

to crank plate

Cracked or
broken

Fuel flow cant be shutoff

(4)

3 (D)

12

Fails closed

Cannot refuel

IV

(1)

3 (D)

Broken

Poppet valve opens; cannot

stop fuel flow

(4)

3 (D)

12

Same as above

1) Pressure test
prior to use
2) Shut off fuel at
source

Bent

Difficult to open or close

valve

III

(2)

3 (D)

Same as above

Missing or
broken

1) Valve may loosen and

prevent complete fuel shutoff

(4)

3 (D)

12

Same as above

2) FOD from pin prevents

valve closure. Fuel may leak

II

(3)

3 (D)

Same as above

Broken

Poppet valve fails open;

cannot stop fuel flow

(4)

3 (D)

12

Same as above

Bent

Difficult to open or close

valve

III

(2)

3 (D)

Same as above

Installed
backwards

Cannot open valve fully

IV

(1)

3 (D)

Missing

Poppet valve opens; cannot

stop fuel flow

(4)

3 (D)

12

Bent or
broken

Difficult to open or close

valve

III

(2)

3 (D)

Missing

Poppet valve opens; cannot

stop fuel flow

(4)

3 (D)

12

Bent or
broken

Difficult to open or close

valve

III

(2)

3 (D)

Improperly
installed

Poppet valve wont fully open

III

(2)

3 (D)

Missing

Poppet valve opens; cannot

stop fuel flow

(4)

3 (D)

12

Bent

Difficult to open or close

valve

III

(2)

3 (D)

Same as above

Same as above

Same as above

31

Valve Link
Nut

Fastens valve link

bolt to crank plate

Missing or
broken

Valve link bolt may back out

(4)

3 (D)

12

Same as above.
In addition, bolt is
also threaded into
crank plate

32

Cotter Pin

Locks valve link nut

Missing or
broken

Nut could back off

(4)

3 (D)

12

Same as above

FOD could prevent complete

valve closure

II

(3)

3 (D)

Pressure test
prior to use

None

IV

(1)

3 (D)

Four screws; two

are sufficient

33

Crank Plate
Screws (4)

Fasten crank plate

to crank handle

Missing 1 or
2

27

SM64349

NR

COMPONENT

FUNCTION

FAILURE
MODE

RESULT OF FAIL

Missing 3 or
4

1) Poppet valve opens;

cannot stop fuel flow

April 2011

HAZARD
CATEGORY
I

(4)

HAZARD
PROBABILITY

REAL
HAZARD
INDEX
(RHI)

3 (D)

12

CORRECTIVE
ACTION
1) Pressure test
prior to use
2) Shut off fuel at
source

34

Crank
Handle

2) Crank handle may pop up

and release fuel

(4)

3 (D)

12

1) Applies force to
open poppet valve

Bent shaft

Difficulty in use (binding)

IV

(1)

3 (D)

2) Prevents collar
from rotating

Broken shaft

1) Poppet valve opens;

cannot stop fuel flow

(4)

3 (D)

12

Same as above

1) Pressure test
prior to use
2) Shut off fuel at
source

2) Crank handle may come

off and release fuel

(4)

3 (D)

12

Same as above

Broken
locking lug

Possible to rotate collar while

refueling; nozzle separates;
massive fuel spill

(4)

3 (D)

12

Prior to refuel,
verify integrity by
attempting to
rotate collar with
handle open
and nozzle
attached to
aircraft

35

Crank ORing

Seals crank shaft

tube

Missing or
broken

Minor fuel leak

II

(3)

3 (D)

Same as above

36

Crank
Packing

Compresses crank
O-Ring

Missing or
broken

Minor fuel leak

II

(3)

3 (D)

Same as above

37

Swivel
Bonding
Ribbon

Provides sliding
contact for
electrical bonding

Missing

Nozzle loses electrical

continuity

III

(2)

3 (D)

Bent

Binding swivel

IV

(1)

3 (D)

38

Dust Cap

Protects nozzle
lugs and valve
(when not in use)

Torn or
missing

None

IV

(1)

3 (D)

39

Handlegrip
Washer (4)

Provides bearing
surface for
handlegrip nuts
and bolts

Missing,
broken or
installed
backwards

None

IV

(1)

3 (D)

40

Secondary
O-Ring

Provides seal for

swivel bearing

Missing

Fuel leak

II

(3)

3 (D)

1) Pressure test
prior to use
2) Shut off fuel at
source

Torn or
broken

Fuel leak

II

28

(3)

3 (D)

Same as above

SM64349

12.0

April 2011

FAILURE MODES AND EFFECTS ANALYSIS HOSE END CONTROL VALVE

12.1

Notes that apply to this analysis:

F.

Hazard category, hazard probability, and real hazard index (RHI) are defined herein.

G.
Visual inspection means examining the regulator for obvious cracks, damage, and broken lugs, prior to initial
pressurization.
H.
Pressure test prior to use means pressurizing the regulator to operating fuel pressure, then removing pressure, prior to
aircraft arrival.
I.
Shut off fuel at source will be the first action for any leak. To further improve operating safety, this procedure should be
used for all refueling operations. In addition, fuel flow should be turned on at the source, not at the nozzle.
J.
12.2

Item numbers referred to in this section are those used in Figure 1.

RISK ASSESSMENT - A risk assessment procedure based upon the hazard probability, as well as hazard severity may be
required to establish priorities for corrective action and resolution of identified hazards. One example is the real hazard index; a
numeric rank ordering of a mathematical combination arrived at by assigning numerical values to the severity category and
probability level.
A.
Hazard Probability - The probability that a hazard will occur during the planned life expectancy of the system can be
described in potential occurrences per unit of time, event, population, item or activity. Assigning a quantitative hazard is generally
not possible early in the design process. A qualitative hazard probability may be derived from research, and evaluation of historical
safety data from similar systems.
Level

Descriptive word

Specific Individual Item

Fleet or Inventory

A (6)

Frequent

Likely to occur frequently

Continuously experienced

B (5)

Reasonably probable

Will occur several times in life of an item

Will occur frequently

C (4)

Occasional

Likely to occur sometimes in the life of an item

Will occur several times

D (3)

Remote

So unlikely, it can be assumed that this hazard

will not be experienced

Unlikely to occur but possible

E (2)

Extremely Improbable

Probability of occurrence cannot be

distinguished from zero

So unlikely it can be assumed that this

hazard will not be experienced

F (1)

Impossible

Physically impossible to occur

Physically impossible

B.
Hazard Severity - Hazard severity categories are defined to provide a qualitative measure of the worst potential
consequences resulting from personnel error, environmental conditions, design inadequacies, procedural deficiencies, or system,
subsystem or component failure/ malfunction.
Severity Category

C.

Descriptive word

Results

(4)

Catastrophic

II

(3)

Critical

May cause death or system loss

III

(2)

Marginal

May cause minor injury, minor occupational illness, or minor system damage

IV

(1)

Negligible

Will not result in injury, occupational illness, or system damage

May cause severe injury, or system damage

Real Hazard Index (RHI) Matrix - (RHI = Hazard Severity X Probability Level)
I

PROBABILITY

A
B
C
D
E
F

(6)
(5)
(4)
(3)
(2)
(1)

(4)
24
20
16
12
8
4

II

SEVERITY
(3)
III (2)
18
12
15
10
12
8
9
6
6
4
3
2

General guidelines for required action.

RHI
1-8

No action required.

9-12

Special precautions required, investigate redesign.

13-24

Hazardous, redesign necessary or procedural control if redesign is impractical.

29

IV (1)
6
5
4
3
2
1

SM64349

April 2011

12.3 FAILURE MODES AND EFFECTS ANALYSIS (FMEA) Refer to Figure 1 for component numbers mentioned in column one.
HAZARD
PROBABILITY

REAL
HAZARD
INDEX
(RHI)

II (3)

E (2)

Uncontrolled pressure
regulation, failed to lock-out

III (2)

D (3)

Broken,
scratched
or nicked

Uncontrolled pressure
regulation. Leakage coming
out of vent port

III (2)

D (3)

Holds inner and

outer pistons
together.

Broken,
missing,
loose or
stripped

Uncontrolled pressure
regulation, failed to lock-out.
Leakage coming out of vent
port

III (2)

D (3)

Stat-o-seal

Used in
conjunction with
screw (item 4).

Broken

Uncontrolled pressure
regulation, failed to lock-out.
Leakage coming out of vent
port

III (2)

D (3)

Spring

Provides biasing
value between
reference pressure
and outlet
pressure.

Broken

Permanent lock-out

III (2)

E (2)

Outer Piston
Seal

Isolate outlet from

inlet when unit is
locked out

Broken or
nicked

Failed to lock-out

III (2)

E (2)

O-Ring

To energize seal
(item 7)

Broken

Failed to lock-out

III (2)

F (1)

Screw

Holds item 11 (seal

retainer) in place

Broken,
missing,
loose or
stripped

Uncontrolled pressure
regulation, failed to lock-out.
Leakage coming out of vent
port

III (2)

D (3)

10

Washer

Used in
conjunction with
item 9 (screw)

Broken

No effect

IV (1)

E (2)

11

Seal
Retainer

Retains Inner
piston seals and
spacers

Broken or
loose

Uncontrolled pressure
regulation, failed to lock-out.
Leakage coming out of vent
port

III (2)

E (2)

12

Quad-Ring

To provide sealing
seat for ball (item
13)

Broken

Failed to lock-out. Failed to

hold locked-out pressure

III (2)

D (3)

13

Ball

To isolate inlet and

outlet during lockout

Broken

Failed to lock-out. Failed to

hold locked-out pressure

III (2)

F (1)

14

Spring

Provides biasing
value between
outlet pressure and
inlet pressure

Broken

Failed to lock-out

III (2)

E (2)

15

O-Ring

To provide sealing
seat for outer
piston (item 2)

Broken

Failed to lock-out

III (2)

D (3)

16

Spacer

To provide
segregation
between the two
sets of seal/O-ring
(item 17 and 18)

Broken

Uncontrolled pressure
regulation, failed to lock-out.
Leakage coming out of vent
port

III (2)

E (2)

17

Seal

Isolate working
fluid from reference
fluid

Broken

Uncontrolled pressure
regulation, failed to lock-out.
Leakage coming out of vent
port

III (2)

E (2)

18

O-Ring

To energize seal
(item 17)

Broken

Uncontrolled pressure
regulation, failed to lock-out.
Leakage coming out of vent
port

III (2)

E (2)

NR

COMPONENT

FUNCTION

FAILURE
MODE

Retaining
Ring

Retain piston
assembly against
spring force.

Broken,
missing or
loose

Unrestrained piston assembly

Outer Piston

Regulate outlet
pressure.

Broken,
scratched
or nicked

Inner piston

Isolate working
fluid from reference
fluid.

Screw

HAZARD
SEVERITY

RESULT OF FAIL

30

CORRECTIVE
ACTION
Inspect prior
to installation
into system

Inspect prior
to installation
into system

SM64349

April 2011

HAZARD
PROBABILITY

REAL
HAZARD
INDEX
(RHI)

II (3)

E (2)

External leakage

II (3)

E (2)

Missing or
loose

Contamination of inner piston

cavity

IV (1)

E (2)

Inspect prior
to use

To provide
containment for
balls (item 27) and
to prevent external
leakage

Broken or
loose

External leakage

II (3)

E (2)

Inspect prior
to use

O-Ring

To prevent external
leakage.

Broken

External leakage

II (3)

E (2)

27

Ball Bearing

To secure
mechanical
connection to
mating part

Broken

Damage ball race

IV (1)

F (1)

28

O-Ring

To prevent external
leakage.

Broken

External leakage

II (3)

E (2)

Inspect prior
to installation
into system

29

Housing
Assembly

House all
components

Cracked

External leakage. Total failure

I (4)

E (2)

Inspect prior
to use

29
B

Outer Wear
Ring

Broken

Exposing aluminum housing

ball bearing race to wear.

III (2)

E (2)

29
C

Inner Wear
Ring

Provide harden
bearing surface to
protect aluminum
housing

31
A

Continuity
clip

To provide
electrical continuity
(bonding) to mating
component

Broken

No ESD protection

II (3)

E (2)

HAZARD
SEVERITY

FAILURE
MODE

RESULT OF FAIL

To prevent external
leakage.

Broken

External leakage

O-Ring

To energize seal
(item 19)

Broken

21

Breather
Assembly

To prevent
atmospheric
contaminants from
entering inner
piston cavity

25

Screw
Assembly

26

NR

COMPONENT

FUNCTION

19

Seal

20

31

CORRECTIVE
ACTION
Inspect prior
to installation
into system

Aerospace Group
Conveyance Systems Division
9650 Jeronimo Rd
Irvine, CA USA 92618
Ph: (949) 452-9500
Fax: (949) 452-9992