SM 60427

Carter
Model 60427
Underwing Refueling Nozzle
SM60427

Maintenance Manual

Model 60427 Nozzle

carter ground fueling
A Division of J.C. Carter Co. Inc.
UNDERWI NG NOZZLES
FBO OPERATIONS
MODELS 64049
Carter now offers an underwing nozzle designed for small
airfield, FBO, use with a new easy to use quick disconnect
for strainer checking, with or without an effective dry
break. The underwing nozzle, a derivation of the 64348,
utilizes the Carter Unisex Coupling as the disconnect.
Along with this underwing nozzle, Carter also offers an
interchange fitting to effect easy underwing to overwing or
Closed Circuit Refueling (CCR) Nozzle interchange with a
minimumof fuel spillage.
64049B2KEJ
Underwing Nozzle with 60-mesh Strainer,
Unisex Coupling Inlet with Dry-break
and Dust Caps for both Unisex Couplings
FEATURES:
Unisex Coupling used for quick disconnect or dry
break disconnect.
Designed for small airport applications on 1 or 2
hoses.
Overwing or CCR Nozzle to Underwing Nozzle
interchange fitting available.
Integral swivel, independent of quick disconnect,
makes connection to aircraft easy.
Connects to 3-lug international standard aircraft
adapter.
Self-adjusting pressure loaded nose seal. No
mechanical adjustments or springs used. Leak free
under extreme side loads, worn adapters and extreme
temperatures.
Long-life stainless steel lead-in ramps interface aircraft
adapter for longer life.
Positive interlock - nozzle cant be removed from
aircraft in open position.
Flow control handle, of high strength zinc aluminum
alloy, fully protected fromdamage.
Replaceable bicycle-type handles and grips standard for
ease of operation, circular grip also available.
Two threaded ports in nozzle body for simultaneous
vacuumbreaker and product sampling fitting
installation are standard.
Lightweight and rugged.
Modular construction.
1 & 2 female NPT & BSPP threaded quick
disconnect inlets optional.
1 & 2 female NPT & BSPP threaded quick
disconnect dry break inlets optional.
Optional 40-, 60- & 100-mesh screens retained with
snap ring for ease of removal.
Bonding cable, vacuumbreaker - optional.
Bulletin 64049 9/99
671 W. 17th St., Costa Mesa, CA 92627 (949) 548-3421 FAX (949) 631-2673 E-mail cgf_sales@jccarter.com
See our web page at http://www.jccarter.com
BACK
SM60427

EATON Aerospace Group SM60427 May 2013 Page 2

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 .................................................................................... 5
5.0 Special Tools ............................................................................................ 8
6.0 Disassembly ............................................................................................. 8
7.0 Inspection ................................................................................................. 9
8.0 Reassembly .............................................................................................. 9
9.0 Test .......................................................................................................... 11
10.0 Illustrated Parts Catalog .......................................................................... 11
Figure 1 ............................................................................................................ 14
Figure 2 ............................................................................................................ 15
Figure 3 ............................................................................................................ 16
Figure 4 ............................................................................................................ 17
Figure 6 ............................................................................................................ 18
11.0 Failure Modes And Effects Analysis Nozzle ......................................... 19
12.0 Failure Modes And Effects Analysis Hose End Control Valve.............. 23

SM60427

Maintenance, Overhaul & Test Instructions
Carter
Model 60427
Underwing Refueling Nozzle

1.0 INTRODUCTION
This manual furnishes detailed instructions
covering the maintenance and overhaul of
Eatons Carter product line Model 60427
Underwing Refueling Nozzle and its various
options. For the maintenance of options to the
basic Model 60427 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.
In this latest issue, the new part numbering
system required to identify the nozzle is also
fully explained. (See Section 3.0).
Model 60427 nozzle is designed to mate all
international standard aircraft adapters made in
accordance with MS24484, MS29514 or
equivalent.
2.0 EQUIPMENT DESCRIPTION
Model 60427 nozzle is a 2-inch underwing
refueling nozzle. It is designed for use with all
grades of commercial and military jet fuels. Its
operating pressure range is 0 - 200 psi with a
rated flow of 600 gpm. The nozzle will have a
pressure drop of approximately 3 psi at rated
flow when fully opened. The operating
temperature range is -35 F to 150 F (-37 C to
66 C). The basic nozzle would be procured as
model number 60427, which would include the
standard handle grips and nose seal. Other
options that are available to build a nozzle to
specific specifications are listed in the table
shown in Section 3.0. The exploded view, Figure
2, includes options D, E and T. Other available
options are either shown in the other exploded
views or in the separate manuals referenced as
accessory to this manual.
3.0 TABLE OF OPTIONS & ORDERING INFORMATION
The basic Model 60427 is available with a
variety of options to customize it to meet
specific requirements as listed in the table
below. The various options, when compatible,
may be combined and listed following the model
number 60427 to achieve a complete unit. The
model number of a complete nozzle consists of
four basic parts as illustrated below.

PART 1 Model Number

60427
PART 4 Letter describing the inlet thread size & type

PART 3 Number describing the male adapter required to mate the desired inlet
configuration
PART 2 Options B-Z describing various changes to the basic configuration

SM60427

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 Description Option Letter Description
*B 60 mesh strainer ***H Adds drag ring
*C 100 mesh strainer R Flight refueling male half
D Grounding cable S Stirrup handle package
E Vacuum breaker T Pressure gauge (obsolete)
**F3 35 psi regulator V
Deletes handles (nozzle shipped less
handles)
**F4 45 psi regulator Y Russian nose seal (obsolete)
**F5 55 psi regulator Z Arctic weather nozzle
G Adds 15 handles
* Options B & C only available when a male half from part 3 or option R is specified.
** To obtain a nozzle with two regulators, specify two options in series - F5F4 results in 55 and 45 psi units with the 55 psi
unit assembled as the one nearest the inlet. It should also be noted that the "-555" version of the hose end regulator no
longer exists, it has been replaced by the F5. The "-555" was a 55 psi unit with a gold anodized body for identification. All
F5 regulators have a gold alodined stripe around the body.
*** Can be used only with any option F. Can not be used with options 3-5 or 7-9 from part 3 below.

PART 3
One of the numbers on the following page must be included as Part 3, as indicated above, to specify the type of
inlet configuration desired. The nozzle may be ordered with the inlet terminating in an adapter half only, if desired.
In this case leave Part 4 blank. If a female half, either quick disconnect or dry break of some configuration is
desired, Part 4 must be completed.
Option
Letter
Description Option
Letter
Description
3 Adds ball valve (Model 64015). [Refer to
product brochure TF100-88 for more details to
order and or options available]
4 Adds male adapter half to mate 64001 swivel
quick disconnect when the regulator is used
(any F option). (44185)
3D Adds glass inspection port to ball valve 5 Adds male adapter half to mate 64001 swivel
quick disconnect when used without regulator
3E Adds drag ring to ball valve. (Use instead of
option H from part 1 above)
6 Adds male adapter half (43046) to mate
standard female quick disconnect (43108) & old
style dry break QD (60672-1)
3DE Adds ball valve with glass inspection port and
drag ring
7*** Adds male adapter half to mate 61154 dry break
when the regulator is used (any F option).
(44185)
J** Adds handle spanner for
operation/inspection.
8*** Adds male adapter half to mate 61154 dry break
quick disconnect when used without regulator
R** Adds hex key for defuel operation 9 Adds male adapter half to mate with high flow
female QD (includes 100 mesh screen). Only
available as complete QD with 3" JIS inlet thread.
(42275-3) Specify together with "U" from part 4.
** Adds options to number 3 of Part 3 above, only
*** Safety clip (P/N 210641) for the 61154 dry break QD is considered FOD (Foreign Object Debris) and is not
included on military nozzle assemblies, however, it can be added as a no cost option.
SM60427

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 Description
Option
Letter Description
H Inlet thread - 2" NPT N Inlet thread - 2" BSPP
K Inlet thread - 2" BSPP P Inlet thread - 2" NPT
L Inlet thread - 3" NPT U Inlet thread - 3" JIS (only available with option 9
from part 3 only)
*M Inlet thread - 3" BSPP Z Inlet thread - 3" JIS (only available with option 6
from part 3 only)
* Not available with ball valve, option 3 from Part 3 above.
Examples: 60427BDF36H - Nozzle with 60 mesh screen, grounding cable, 35 psi regulator and 2 1/2 NPT
40679-1 QD.
60427CF5F57K - Nozzle with 100 mesh screen, two 55 psi regulators and 2 1/2 BSPP 61154JK dry break QD.
60427C8K - Nozzle with 100 mesh screen and 2-inch BSPP 61154DK dry break.

The following table should be used to determine the service manual to be used in the maintenance, repair or
replacement of parts designated by option letters to the basic 60427 nozzle.

Option
Letter Part Number Service Manual
Option
Letter Part Number Service Manual
B 41767-60 SM40679 4 44185 SM64001
C 41767-100 SM40679 4H, K-P 64001H, K-P SM64001
D 41768 SM60427 5 44700 SM64001
E 41599 SM60427 5H, K-P 64001H, K-P SM64001
F* 60129-1* SM60129-1 6 43046 SM40679
G 43003-2 SM60427 6H, K-P & Z 40679- SM40679
R 41600 SM427MISC 7 44185 SM61154
S 43003-3 SM60427 7H, K-P 61154H, K-P SM61154
T** 41770 SM60427 8 44700 SM61154
Y** 29649 & 29650 SM60427 8H, K-P 61154H, K-P SM61154
Z 47101 SM60427 9U 42275-3 SM42275
3H, K, L, N, P 64015 SM64015

* Three different regulators are available. Refer to the following pages regarding part numbering for more details.
** Option T pressure gauge and option Y, Russian nose seal, available only as long as inventory of the parts is
available. Nozzles with the old style dry break Model 60672-1 were sold under options TT through YY to the
basic nozzle. Model 60672-1 is out of production and has been superseded by Model 61154 dry break quick
disconnect. The male and female halves of the 61154 are not interchangeable with either the 60672-1 series
male and female halves. The entire dry break disconnect must be replaced. The male half adapter, 43046, is still
available as a spare part. However, if the female half is required as a replacement for a 60672-1, a complete
61154 (appropriate options specified) will have to be ordered.
4.0 SAFETY INSTRUCTIONS
There are several safety interlock features
designed into the Model 60427 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,
Section 10.0, to identify individual parts during
the following discussion.
4.1 COLLAR ASSY LOCK AND INDEX PINS
Examination of the connection end of a
disengaged nozzle not connected to an adapter
discloses the three Collar Lock Pins (15) and
three Index Pins (17) installed between the
Collar (9) and the Nose Seal (12) or (12A). The
three spring loaded Collar Lock Pins (15)
engage three cutouts (arched shaped windows)
in the flange of the Collar (9) when the Collar is
in the fully disengaged position. These Collar
SM60427

Lock Pins (15) prevent accidental rotation of the
Collar of the disengaged nozzle. One of the
three cutouts in Collar (9) is normally elongated
more than the other two.
With the Collar (9) locked in the disengaged
position, the flat portion of a ramp integral to the
Collar (9) is positioned over a flat on the Crank
Handle (21) or (21A) in a manner that prevents
opening the Poppet (11 or 11A).
When connecting to an aircraft, the three Index
Pins (17) mate with three slots in a serviceable
MS24484 Adapter Flange to index the nozzle to
the flange so the Collar (9) mates with the
flange lugs during engagement and prevents
disengagement of the Collar (9) from the flange
without releasing the three spring loaded Collar
Lock Pins (15) to the Collar (9) lock positions.
4.2 CRANK HANDLE/COLLAR INTERLOCK AND
OVER CENTER LINKAGE
Examination of the center portion of the Crank
Handle (21) or (21A) on a disengaged nozzle
discloses the fact that a flat edge of the Crank
Handle (21) or (21A) is beneath the flat portion
of a ramp that is integral to the Collar (9). With
the Collar (9) locked by the Collar Lock Pins
(15), the Collar (9) ramp prevents rotation of the
Crank Handle (21) or (21A) to the poppet open
position.
When the Collar (9) is fully engaged to a
serviceable MS24484 Adapter the Collar ramp
clears the Crank Handle (21) or (21A) and
permits rotation to the open position.
With the Crank Handle (21) or (21A) fully open,
the round portion of the Crank Handle (21) or
(21A) prevents rotation of the Collar (9) in the
disengage direction until the Crank Handle (21)
or (21A) has been fully closed.
These interlocks are designed to prevent
accidental opening of the poppet while
disengaged, or accidentally disengaging a
nozzle with the poppet open.
The poppet operating internal linkage design is
such that the linkage is "over center" at each
extreme of travel for Crank Handle (21) or (21A)
to fully open against internal mechanical stop or
to fully closed against internal mechanical stop.
Thus, internal pressure against a closed poppet,
when the linkage is against the closed
mechanical stop, provides a force only in the
closed direction.
In a similar manner, with the Crank Handle (21)
or (21A) in the fully open/mechanical stop
position, the 50 lb. force applied by the
MS24484 Adapter Poppet Spring provides a
force to maintain the open direction.

4.3 SAFETY INSPECTIONS
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.
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 (17) are intact, in place, and
not excessively worn or damaged. Verify that all
three Collar Lock Pins (15) are intact,
undamaged and are extended to engage all
three cutouts in the Collar (9) and physically
prevent Collar (9) rotation.
This inspection can be accomplished without
interruption of the normal operating procedure
and without adding appreciably to the operation
time by training the operator to automatically
observe the connection end of the nozzle upon
disconnection from the aircraft. If the Collar
Lock Pins (15) are not extended and engaged in
all three cutouts in the Collar (9), the operator
should squeeze the Crank Handle (21) or (21A)
and Handle (6), (6A) or (6B) together while
observing the connecting end of the nozzle. This
should cause the Collar Lock Pins (15) to
"spring" into the cutouts in the Collar (9). If not,
then the nozzle should be taken out of service. If
the Collar Lock Pins (15) do not spring into their
correct position, it could mean that the aircraft
adapter is defective and should be inspected
(see paragraph 4.3.3) and reported as possibly
being defective.
B. Upon engagement to an aircraft and
opening the nozzle, but before operating the
deadman control, it is recommended that the
operator attempt to remove the nozzle from the
aircraft. This should not be possible. If it can be
removed, either the nozzle was never fully
engaged onto the aircraft or needs repair, or the
aircraft adapter, is in need of repair.
4.3.2 NOZZLES INSPECTIONS - MONTHLY BASIS
The following inspections of the nozzle are
recommended to be conducted on a monthly
basis as a minimum:
A. Inspect the connection end and verify that
the three Index Pins (17) are intact and in place.
Verify that the three Collar Lock Pins (15) are
intact and in place and extended and engaging
all three cutouts in the Collar (9) and physically
preventing Collar (9) rotation. Check the Bearing
SM60427

Plate (14) containing the pins for possible
cracks.
B. Hold the nozzle with the outlet or connecting
end facing such that it can be observed. Apply
pressure on the Collar (9) in the direction to
connect the nozzle to an aircraft, counter-
clockwise, to take up the slack and inspect the
relative location of the three Lock Pins (15) with
respect to the cutouts in the Collar (9). The two
Lock Pins (15) that are engaged in the normally
narrower cutouts should be resting against the
edge of their respective cutouts. If there is a
space between the third Lock Pin (15) and the
edge of the normally larger cutout, the collar is
still in functional condition. If all three Lock Pins
(15) are resting against the edge of their
respective cutouts (there is no space), the Collar
(9) may no longer be in a functional condition and
should be replaced if it fails the next step of the
inspection.
C. With the nozzle being held in the position
described above, attempt to open the nozzle
with the Crank Handle (21) or (21A). The nozzle
should be prevented from opening by the
interference between the Collar (9) and the
Crank Handle (21) or (21A). If the nozzle can be
opened, it should be removed from service and
repaired.
D. Inspect the Crank Handle (21) or (21A) and
the adjacent ramp surface of the Collar (9) and
verify that neither part is damaged or has
missing pieces that permit the Crank Handle
(21) or (21A) to be rotated to the open position
with the nozzle disengaged or that will allow the
Collar (9) to rotate to the disengaged position
when the Crank Handle (21) or (21A) is open.
Broken or missing parts can result in dangerous
fuel spills while refueling aircraft.
E. Verify that the Crank Handle (21) or (21A)
is in the fully closed position (against internal
mechanical stop). This is necessary to assure
that the linkage is over center so internal
pressure can not force the poppet open during
the Collar (9) engagement.
4.3.3 AIRCRAFT ADAPTER INSPECTIONS
The following inspections of the aircraft adapter
are recommended to be carried out at each
refueling operation to assure that one is
connecting to a safe adapter:
A. Visually check for bent, broken, missing or
excessively worn lugs or slots. Worn slots are
easily detected. A normal slot will have a slight
machine broken edge (chamfer of .030 inch
(0.762 mm)). If the edge is worn such that the
corner is badly distorted and enlarged it should
be inspected more closely and accurately.
Adapter Wear Gauge, 61657-2, should be
utilized to check the width and thickness of the
lugs if they appear to be worn. Wear of the
thickness dimension of the lug will promote
premature nose seal leakage. Wear of the width
of the lug combines with slot wear in defeating
the nozzle interlock.
B. Visually check the three slots for excessive
wear. Excessive wear can permit
disengagement of a nozzle without release of
the three Collar Lock Pins (15) and may permit
accidental poppet opening on the disconnected
nozzle. The use of Wear Gauge 61657-2 will
provide a "no-go" check for the slots.
C. If any of the above conditions are observed,
and or the gauge proves the adapter to be
defective, the refueling operation should be
continued only with extreme caution. The
nozzle, upon disconnection, should be checked
in accordance with paragraph 4.3.1.A.
4.3.4 POPPET-SHAFT RETENTION INSPECTION
This inspection procedure must be
conducted following the removal and
reinstallation of the Poppet (11 or 11A) from
the Shaft (38).
Using Eatons Carter brand part number
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 suitable container. Even if
the ball valve or a dry-break disconnect is
utilized, there will be a small quantity of trapped
fuel in the nozzle.
Check to see if there is a Cotter Pin (10)
installed through the slotted poppet and the hole
in the shaft. The pin must be installed in the
hole that is completely within the slotted area of
the poppet and the hole that allows for proper
poppet nose seal adjustment
Older nozzles will have a Cotter Pin (10)
that has an overall length of approximately 1.05
inches (26.7 mm). The pin on the newer nozzles
will be approximately 1.35 inches (34.3 mm)
long. If the new longer Cotter Pin (10), part
number GF24665-302, is available it is
recommended that the existing pin be removed
and the new Cotter Pin (10) installed in accordance
with Figure 6. If the new pin is not available, it is
recommended that the Cotter Pin (10) be checked
to assure that the longer leg is bent into a partially
circular loop such that the loop is as close to the
shaft as possible. The shorter leg should be
bent to an angle as close to 90 as possible.
Grasp the Poppet (11 or 11A) with one hand
and holding the nozzle with the other attempt to
un-screw the (11 or 11A) from the Shaft (38). The
poppet will move a slight amount taking up the
slack between the slot in the (11 or 11A), the hole
in the Shaft (38) and the Cotter Pin (10).
If all is correct close the nozzle and remove
the adapter flange. Put the nozzle back in service.
SM60427

5.0 SPECIAL TOOLS
The following special tools are recommended
for proper repair and or overhaul of the nozzle:
6958CG or 6958CH adapter or equivalent.
61657-2 adapter wear gauge
64000 poppet adjustment gauge
The above items are available from your Eaton
Carter brand distributor.
6.0 DISASSEMBLY
6.1 Remove nozzle from end of hose at quick
disconnect. Refer to the appropriate service
manual depending upon type of swivel
disconnect utilized.
SM40679 Standard 60427 nozzle disconnect
SM42275 High flow disconnect (JIS thread only)
SM427MISC Miscellaneous male half adapters
not associated with a complete
disconnect
SM60129-1 Hose end control valve (HECV)
SM60672-1 Old style dry break disconnect
SM61154 New style dry break disconnect
SM64015 Ball valve
If Drag Ring, option H, is present it is
sandwiched between the male and female
halves of the disconnect. Set aside for later
inspection.
6.2 Remove the cover assembly (1) from nozzle.
Before proceeding further it is recommended
that the inspections detailed in paragraph 4.3.2
be conducted to get an overall picture of the
condition of the nozzle. Take special note of the
wear check of the Collar (9) detailed in 4.3.2.B.
If all three cutouts of the Collar (9) are touching
the Lock Pins (15), the Collar (9) should be
replaced during overhaul.
If the Handles (6), (6A) or (6B) are to be replaced,
remove hardware items (2, 4 & 5). If they do not
need replacing, remove only the that Handle (6),
(6A) or (6B) that is farthest away from the Crank
Handle (21) to allow the indexing lug on the Body
(39) to pass through the slot in the Collar (9). On
later models, the regular stick type Handles (6 or
6A) are an assembly with replaceable Grips (6C)
held in place with Screw (6E) and Washer (6D).
Remove Grip (6C) from Handle (6F or G) only if it is
necessary to replace it.
6.3 Using a sharp knife, cut the Bumper (7) to
remove it from the Collar (9).
6.4 Push at one end of the collar Bearing (8) to
cause the other end to protrude from groove.
Using pliers, pull the collar bearing out of
groove. On parts where the Bearing (8) is
difficult to remove it is suggested that the outlet
end of the nozzle be soaked in light motor oil
over night to assist in removing it.
NOTE: Do not engage nozzle onto an adapter.
This will create a load on Bearing (8).
6.5 Remove nozzle Collar (9) from Body (39) by
aligning the groove in the Collar (9) with square
boss on the side of the Body (39).
6.6 Turn Crank Handle (21) or (21A) to open Poppet
(11 or 11A).
6.7 Remove Cotter Pin (10) and unscrew the
Poppet (11 or 11A) from the Shaft Assembly
(38). Older nozzles will have a Poppet (11) that
is green in color (Teflon coated) while the "Y"
option Poppet (11A) is black. Newer nozzles will
have a golden colored (anodized aluminum)
Poppet (11) as standard. The nozzles with this
poppet also have a Shaft (38) which has two
holes drilled in the threaded end. The golden
colored Poppet (11) can only be utilized if there
are two holes present. Rework instructions to
add the second hole to allow the use of the
lower cost Poppet (11) are included as Figure 5.
On the golden colored Poppet (11), do not try to
remove the permanently assembled shroud on
the curved side of the unit.
6.8 The Nose Seal (12 or 12A) may be removed.
Remove Snap Ring (13) from Seal (12) or
(12A). Lift off Plate (14).
6.9 The three Lock Pins (15), three lock pin Springs
(16), three Index Pins (17) and O-ring (18) may
now be removed.
6.10 After removal of the Screw (19) and the
Lockwasher (20), the Crank Handle (21) and
Washer (28) may be removed. Newer models
utilize a single piece Crank Handle (21A) it may
be disassembled from the nozzle by removing
Pin (21B).
6.11 Remove the Lockwire (29) from the Bushing
(30). Note method of lockwiring so that it may be
duplicated on reassembly.
6.12 Using needle-nose pliers, remove the Cotter Pin
(36).
6.13 Remove the Bushing (30), o-ring Spacer (31),
O-ring (32), two Washers (34), two Wave
Washers (33), and Gasket (35).
6.14 The Crank (37) and Shaft Assembly (38) may
now be removed from flange end of Body (39). It
is not recommended that the Shaft Assembly
(38) be disassembled further. If replacement is
required, replace as an assembly.
SM60427

6.15 The plugs (40) or Vacuum Breaker (46) do not
have to be removed unless replacement is
necessary.
7.0 INSPECTION
7.1 It is recommended that all O-rings (18) and (32),
Gasket (35) and Nose Seal (12) or (12A) be
replaced upon every overhaul.
7.2 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:
The hole in Shaft Assembly (38) shall not
exceed 0.317 inches (8.052 mm) in diameter.
Check the looseness in the riveted
attachment of the Shaft Assembly (38).
Maximum looseness of this joint shall not
exceed 0.013 inches (.330 mm). Check
looseness by holding threaded end in a vise,
push link end toward threaded end to its stop
and lightly scribe a line on the link along the
clevis end of the rod. Pull the link directly away
from the rod and scribe another line. Measure
the distance between the scribed lines with a
vernier caliper to determine the looseness.
Measure the diameter of the boss on the
Crank (37) that mates with Shaft Assembly (38).
It shall not exceed 0.313.
Measure the small hole through the boss of
the Crank (37) through which Cotter (36) is
inserted. If the hole is 0.115 or larger, it is
recommended that Cotter (36) part number be
revised to the oversized one, 82267-2 be used
to prolong the life of the Crank (37).
Check Bearing (8) to be sure it is not worn
below 0.245 inches (6.223 mm) diameter over
more than 50% of its length. The ends may be
chamfered to remove any tool marks caused by
the removal operation. The chamfering should
not extend for a length of more than 0.250
inches (6.350 mm).
Check Pin (17) for damage or cracks. Roll on
a flat surface to check for straightness. Replace
any suspect pin.
Measure diameter of the two groups of three
larger holes in Plate (14). If larger holes are
elongated or exceed 0.253 inches (6.426 mm)
diameter or the smaller ones are elongated or
exceed 0.222 inches (5.639 mm) the Plate (14)
should be replaced.
Measure the main diameter of the Crank
(37). It shall not be less than .493 inches
(12.560 mm).
Measure the through bore of the Bushing (30).
It shall not exceed 0.499 inches (12.675 mm).
Attach the Crank Handle (21) or (21A) to the
square boss on the Crank (37) using the
appropriate hardware. If the Crank Handle (21
or 21A) is not held tightly to the Crank (37) the
handle should be replaced.
If Drag Ring (53), option H, is present
inspect to determine if the part is still capable of
protecting the HECV body. If the outside
diameter of the Drag Ring (53) is less than 4.60
inch (117 mm) replace it.
8.0 REASSEMBLY
Reassemble in reverse order of disassembly,
noting the following:
8.1 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, Federal
Specification P-D-680 or equivalent, and dry
thoroughly with a clean, lint-free cloth or
compressed air.
WARNING:
Use cleaning solvent in a well-ventilated
area. Avoid breathing of fumes and
excessive solvent contact with skin. Keep
away from open flame.
NOTE: A light coat of petroleum jelly can be
applied to all o-rings, springs, and screws for
ease of installation.
8.2 The Crank (37) and Shaft Assembly (38) may
now be inserted in the nozzle body (39) with the
shaft portion of the Crank (37) extending from
the boss on the side of the nozzle Body (39).
The Cotter Pin (36) may be installed with the
use of needle nose pliers taking care to bend
both ends over to secure it.
8.3 Install the Gasket (35) onto the Bushing (30).
8.4 Install and tighten the Bushing (30) to 120-150
in.-lb. (138-173 kg-cm) to be held in place with
Lockwire (29). Insert the two Wave Washers
(33) and two Washers (34) alternately (refer to
Figure 1), the O-ring (32), the o-ring Spacer
(31), and the Washer (28).
8.5 Install the three lock pin Springs (16), three
Lock Pins (15), three Index Pins (17) and O-ring
(18).
8.6 Install the Plate (14) onto the Seal (12 or 12A).
Install Snap Ring (13). The installation of the
Ring (13) is optional. Nozzles coming from the
SM60427

factory will continue to contain this part. If the
Snap Ring (13) is not used, it is possible to
replace the Nose Seal (12) or (12A) without
removing the Collar (9). One will have to be able
to open the nozzle without it being installed to
an adapter. A standard three lug adapter flange
with the three lugs removed will serve nicely for
this application. It should be noted that when the
nozzle is opened in this manner, the Nose Seal
(12) or (12A) may follow the Poppet (11 or 11A)
out of the nozzle. If this is not acceptable, either
use the Ring (13) or simply apply pressure by
hand to the Nose Seal (12) or (12A) as the
nozzle is opened to keep it in place.
8.7 Install the Seal (12) or (12A), Plate (14) and
Ring (13), if used, into the nozzle Body (39),
being careful not to displace O-ring (18). Install
this assembly of parts so the three Index Pins
(17) and three Lock Pins (15) pass through the
six holes in the Plate (14).
8.8 Install the Collar (9) on the Body (39) matching
the groove in the Collar (9) with the square boss
on the body. Secure by inserting Bearing (8) into
the Collar (9) bearing groove. The Crank Handle
(21) or (21C) may now be installed and held in
place with the use of the Lockwasher (20) and
the Screw (19) or Pin (21B).
8.9 Use the Crank Handle (21) or (21A) and turn the
Crank (37) position to install the Poppet (11 or
11A).
Before inserting the Cotter Pin (10), adjust the
Poppet (11 or 11A) to .020 - .040 inch (.508 -
1.016 mm) above the top of the face of the
collar. If the golden colored Poppet (11) is
utilized the Shaft (38) must have two holes
present in the threaded portion. If there is only
one hole the green Poppet (11) must be used or
the Shaft (38) must be reworked in accordance
with Figure 5.
With the Crank (37) rotated to the full closed
position, the top of the Poppet (11) or (11A)
should be approximately in the middle of the
concave surface area of the nose seal.
Use of the Poppet Adjustment Gauge, 64000,
will facilitate the achievement of the correct
adjustment.
8.10 Install the Cotter Pin (10) in the Shaft Assembly
(38) as shown in Figure 6. Be sure that both
legs of the Cotter (10) are bent. Turn Crank
Handle (21) or (21A) to closed position. Make
sure the Cotter Pin (10) ends are securely bent
over to retain in place.
8.11 Install Bumper (7). It is best to warm the Bumper
(7) in water at 160-180F to soften before
pressing onto Collar (9).
8.12 Install Handle (6), (6A) or (6B) being sure to first
insert it through the loop which is a part of the
Cover (1) to retain it. Use the appropriate
hardware items (2, 4 & 5) to secure the Handle
(6), (6A) or (6B) in place. If, on later models, the
Grip (6C) is to be replaced attach it to Handle
(6F or 6G) with Screw (6E) and Washer (6D).
Cover (1) can now be placed over outlet of unit.
8.13 Accessories, such as quick disconnects, dry
break quick disconnects and hose end
regulators can be installed with the hardware
and o-ring provided with each.
8.14 Option D grounding cable can be installed by
inserting the end of the Cable Assembly (45A)
into the hole in the boss on the Body (39) as
shown in figure 2. Ball (45B) is first dropped into
the threaded hole and then Bolt (45C) is
fastened against the Ball (45B) and Cable (45A)
to retain it in place.
8.15 Option E, Vacuum Breaker (46) is installed in
lieu of one of the Plugs (40). Do not use more
than 1 wraps of Teflon tape when installing it.
Tighten only to seal, the hexagon head should
not touch the Body (39) since this is an
American NPT type tapered thread.
8.16 Option T Gauge (47) is shown in Figure 2. This
option includes, in addition to the actual gauge,
a guard to protect the gauge and two screws for
mounting the guard. Screws (47A) are longer
than the normal screws furnished with the
disconnects and regulators to account for the
extra thickness of the Guard (47B). The Gauge
is mounted in the NPT port provided in the Body
(39). Again use no more than 1 wraps of
Teflon tape for seal.
8.17 Safety Clip (50), as shown in Figure 3 is
available only with options 4, 5, 7 & 8 (Part 3).
The Clip (50) is installed in the groove adjacent
to the red sleeve on the dry break disconnect to
prevent the inadvertent movement of the sleeve
until the Clip (50) is moved to the groove closest
to the hose end of the unit.
SM60427

9.0 TEST
The nozzle should be tested as a complete unit,
including the appropriate quick disconnect, dry
break and/or regulator.
9.1 Test conditions
Test media shall be Stoddard Solvent (Federal
Specification P-D-680), JP-4 per MIL-J-5624D
at 75 + 15F, Jet A or equivalent.
9.3 Functional Test
9.3.1 The nozzle shall be inserted and locked into a
test adapter and the nozzle valve actuated by
use of the Crank Handle (21) or (21A) 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 (5) 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.
10.0 ILLUSTRATED PARTS CATALOG
Table 1.0 tabulates the parts and sub-assemblies comprising the 60427 nozzle. The item numbers of the table are
keyed to the exploded views of the regulator diagrammed in Figures 1, 2, and 3.

TABLE 1.0
Item Part Number Description
Units/
Assy Nozzle Option
Spares/10
units/Yr
1 207799 Cover assembly 1 All 10
No number 43003-1 Handle assy set, 10" (Note 10) 1 All but G, S & V 2
2 MS21042-4 Nut, self-locking 2 All -
3 Left intentionally blank
4 GF4-13A Bolt, hex head 2 All -
5 GF960-416 Washer 4 All
6 203241-1 Handle, 10" 2 All but G, S & V
6C 207808 Grip 1 All but S & V 5
6D GF960-516 Washer 1 All but S & V -
6E GF16997-78L Cap screw 1 All but S & V -
6F 220000 Handle 1 All but G, S & V -
No number 43003-2 Handle assy set, 15" (Note 10) 1 G 2
5 GF960-416 Washer 4 All -
6A 203241-2 Handle, 15" 2 G -
6C 207808 Grip 2 All but S & V 5
6D GF960-516 Washer 2 All but S & V -
6E GF16997-78L Cap screw 2 All but S & V -
6G 220001 Handle 2 G
No number 43003-3 Handle assy set, stirrup (note 10) 1 S 2
5 GF960-416 Washer 4 All -
6B 200479 Handle, stirrup 2 S -
7 23622 Bumper 1 All 10
8 23620 Bearing 1 All 3
9 28085 Collar 1 All 2
10 GF24665-302 Cotter Pin 1 All 10
11 26866 Poppet-std. (green-obsolete) 1 All but Y & Z 1
11 210593 Poppet-std. (gold - current Note 11) 1 All but Y 1
11A 29649 Poppet - Russian (black) 1 Y 1
12 209029 Nose seal 1 All but Z 10
SM60427

Item Part Number Description
Units/
Assy Nozzle Option
Spares/10
units/Yr
12A 222486 Nose seal- Arctic 1 Z 10
13 24636 Ring, snap 1 All but Z -
14 24779 Plate 1 All -
15 207789 Lock pin 3 All 3
16 20909 Spring 3 All 3
17 24780 Index pin 3 All 3
18 201201-145 O-ring 1 All 10
18A M25988/1-145 O-ring 1 Z 10
19 220004 Screw 1 All but S 1
20 GF35338-43 Lockwasher 1 All but S -
21 28086 Handle, crank 1 All but S 2
21A 44725 Handle, crank assembly 1 S 2
21B .156-1.000MDP Pin 1 S 5
21C 220128 Handle 1 S -
22-27 Left intentionally blank
28 21706 Washer 1 All 2
29 GF20995C32 Wire, lock A/R All 1 Roll
30 20914 Bushing 1 All 1
31 20910 Spacer 1 All 2
32 201201-014 O-ring 1 All 10
33 22291 Washer wave 2 All 8
34 22290 Washer 2 All 6
35 MS29512-10 Gasket 1 All 10
36 82267-1 Cotter (Note 3) 1 All 2
37 20916 Crank 1 All -
38 40006 Shaft 1 All -
39 41427 Body 1 All -
40 210388 Plug 2 All (1 only option E) 2
41 41600 Adapter, male flight refueling (note 4) 1 R -
42 60129-1* Hose end regulator (note 5) 1 F3, F4, F5 -
43 42275-3 High flow disconnect (JIS thread) (note 6) 1 9U
44 40679-* Quick disconnect (Note 7) 1 6H, K-N, P & Z -
45 41768 Grounding cable kit 1 D -
45A 4646 Grounding cable 1 D -
45B GF19060-1008 Ball 1 D -
45C GF74A11 Bolt 1 D -
46 41599 Vacuum breaker 1 E -
47 41770 Gauge kit 1 T -
47A GF16997-60 Screw 2 T -
47B 29028 Guard 1 T -
47C 80673 Gauge 1 T --
48 61154* Dry break QD (new style) (note 8) 1 7 & 8H, K-N, P -
49 60672-1* DB QD (old style) (note 9) 1 - -
50 210641 Safety Clip 1 STD w/4, 5, 7, & 8 -
51 64001* Low friction swivel quick disconnect (note 13) 1 4 & 5H, K-N, P -
52 64015* Ball valve (note 14) 1 3H, K, L, N, P -
53 220460 Drag ring 1 H 10
54 41767-60
41676-100
Screen assy, 60 mesh
1 6, R -
54A 44373-60
44373-100
1 4, 5, 7, 8 -
55 43046 Adapter, male std disconnect 1 6 -
56 44185 Adapter, short male 1 7, 4 -
57 44700 Adapter, long male 1 8, 5 -

SM60427

Kits
KD604271 Parts necessary for a seal change for the 604276H, 6K-6P & 6Z options (old part number
60427J). Consists of items 10, 12, 18, 28, 32, 33, 35 & 36 above plus 201201-231 &
201201-151 O-rings. Replaces old kit 80676.
KD604272 Parts to make the seal change as in KD60427-1 above plus parts to replace the seals in a
hose end regulator (options F3, F4 or F5). Contains KD60427-1 plus KD60129-1.
KD604273 Parts to include seal changes to the basic nozzle (KD60427-1) plus the o-ring to repair the
old style dry break disconnect 60672-1. Contains KD60427-1 plus 201201-233.
KD604274 KD60427-2 plus KD60427-3 to repair a 60427 nozzle with hose end regulator plus 60672-
1 dry break disconnect.
KD604275 Parts to repair the 60427 nozzle (KD60427-1) plus parts to repair the 61154 new style dry
break disconnect. Contains KD60427-1 plus KD61154-1.
KD604276 Parts to repair the 60427 nozzle plus parts to repair the hose end regulator and 61154 dry
break disconnect. Contains KD60427-1, KD60129-1 and KD61154-1.
KD604277 Parts to provide replacements to allow use of common current production poppet with
60427 nozzle. Contains items 10, 11 (210593) & 38.
KD604278 Parts to perform a major overhaul for the 604276H, 6K-6P & 6Z - consists of items 1, 6C,
7, 8, 9, 10, 12, 18, 28, 32, 33, 35 & 36 above plus 201201-231, & 201201-151 O-rings.
KD604279 Parts necessary for a seal change for the 604276H, 6K-6P options (old part number
60427J). Identical to the 3 kit except the O-ring material is fluorosilicone. Consists of
items 10, 12, 18 (M25988/1-145), 28, 32 (M25988/1-014), 33, 35 (M25988/1-910) & 36
above plus M25988/1-231, M25988/1-151, M25988/1-233 & M25988/1-039 O-rings.

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 an "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. 82267-2 replaces 82267-1 for oversize hole applications.
4. Refer to SM427MISC for parts listing.
5. Refer to SM60129-1 for parts listing. * indicates that there is additional information required to complete the
part number since there is more than one regulator available.
6. Refer to SM42275 for parts listing.
7. Refer to SM40679 for parts listing. * means that there is additional information required to complete the part
number.
8. Refer to SM61154 for parts listing. * means that there is additional information required to
complete the part number.
9. Refer to SM60672-1 for parts listing. * means that there is additional information required to complete
the part number. This item has been superseded by 61154 and is no longer available as an option to the
60427 nozzle.
10. Handle Assy 43003-1, -2 and -3 include all of the parts shown indented under their respective listings.
Example: 43003-1 includes 2 each of items 2-6 (item 6 includes 6C, 6D, 6E & 6F).
11. 210593 Poppet (11) can be used only with Shaft (38) which has two holes present in the threaded end of
the part. Rework instructions are shown in Figure 5).
12. Option Y, nose seal and poppet to fit older Russian aircraft, can utilize either the obsolete 29650 or the
current production 209029 interchangeably.
compete the part number.
compete the part number.

SM60427


TABLE 2.0
Torque Specifications 60427
Fig. Item Part Number Description Torque in.-lb.
1 30 20914 Bushing 120-150 in.-lb. (138 - 173 kg-cm)

FIGURE 1
SM60427


FIGURE 2

SM60427


FIGURE 3
SM60427


FIGURE 4

SHAFT REWORK INSTRUCTIONS
SM60427


FIGURE 6

POPPET SHAFT RETENTION

SM60427


11.0 FAILURE MODES AND EFFECTS ANALYSIS - Nozzle
11.1 Notes that apply to this analysis:
A. Hazard category, hazard probability, and real hazard index (RHI) are defined herein.
B. Visual inspection means examining the nozzle for obvious cracks, damage, and broken lugs, prior to initial
pressurization.
C. Pressure test prior to use means pressurizing the nozzle and attached hose to operating fuel pressure, then removing
pressure, prior to aircraft arrival.
D. Shut off fuel at source will be the first action for any leak. To further improve operating safety, this procedure should be
used for all refueling operations. In addition, fuel flow should be turned on at the source, not at the nozzle.
E. Item numbers referred to in this section are those used in Figure 5.
11.2 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 Descriptive word Results
I (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
C. Real Hazard Index (RHI) Matrix - (RHI = Hazard Severity X Probability Level)
HAZARD SEVERITY
I (4) II (3) III (2) IV (1)
A (6) 24 18 12 6
B (5) 20 15 10 5
PROBABILITY C (4) 16 12 8 4
LEVEL D (3) 12 9 6 3
E (2) 8 6 4 2
F (1) 4 3 2 1
General guidelines for required action.
RHI
1-8 No action required.
9-12 Special precautions required, investigate redesign.
13-24 Hazardous, redesign necessary or procedural control if redesign is impractical.
SM60427

11.3 FAILURE MODES AND EFFECTS ANALYSIS (FMEA) Refer to Figure 5 for component numbers mentioned in column one.
NR COMPONENT FUNCTION
FAILURE
MODE
RESULT OF FAIL
HAZARD
CATEGORY
HAZARD
PROBABILITY
REAL
HAZARD
INDEX
(RHI)
CORRECTIVE
ACTION
1 Cover
Assembly
Protects nozzle
lugs and valve
(when not in use)
Torn or
missing
None IV (1) (1) 3 (D) 3 Visual Inspection
2 Handle Nut
(2)
Holds handle in
place
Missing or
loose
Handle separates IV (1) 4 (C) 4 Use another Nut
4 Handle Bolt
(2)
Holds handle in
place
Missing or
loose
Handle separates IV (1) 4 (C) 4 Use another Bolt
5 Handle
Washer (2)
Provides bearing
surface for handle
bolt
Missing,
broken or
installed
backwards
None IV (1) 3 (D) 3 Use another
Washer
6 10 Handle
Assembly
Rotates collar to
attach or detach
nozzle
Missing, bent
or broken
Cannot attach nozzle IV (1) 3 (D) 3 Use another
Assembly
6A 15 Handle
Assembly
Rotates collar to
attach or detach
nozzle
Missing, bent
or broken
Cannot attach nozzle IV (1) 3 (D) 3 Same as above
6B Handle,
Stirrup
Rotates collar to
attach or detach
nozzle
Missing, bent
or broken
6C Handle Grip
(2)
Provides gripping
surface for handle
Missing or
torn
None IV (1) 4 (C) 4 Replace Grip
6D Handle Grip
Washer (2)
Provides bearing
surface for handle
grip bolt
Missing,
broken or
installed
backwards
None IV (1) 3 (D) 3 Use another
Washer
6E Handle Grip
Cap Screw
(2)
Holds handle grip in
place
Missing or
loose
Handle separates IV (1) 4 (C) 4 Use another
Screw
6F Handle 10 Rotates collar to
attach or detach
nozzle
Missing, bent
or broken
Cannot attach nozzle IV (1) 3 (D) 3 Use another
Handle
6G Handle 15 Rotates collar to
attach or detach
nozzle
Missing, bent
or broken
7 Bumper Ring Protects lug ring on
collar
Missing or
torn
Possible ring damage
(no hazard)
IV (1) 4 (C) 4 Visual Inspection
8 Collar
bearing
Retain nozzle collar
to nozzle body
Broken or
galled
Difficulty in connecting to
aircraft
IV (1) 4 (C) 4 Replace
Missing Unit unusable IV (1) 4 (C) 4 Visual Inspection
9 Collar Secures nozzle to
aircraft receptacle
Cracked or
Broken
aircraft
IV (1) 3 (D) 3 Visual Inspection
Damaged
Ball Grooves
aircraft
IV (1) 3 (D) 3 Same as above
Cracked,
worn or bent
lugs
Improper seal resulting in fuel
leak
II (3) 4 (C) 12 Same as above
Broken or
missing lug
(s)
Nozzle released from aircraft
receptacle resulting in fuel
spill/spray
I (4) 3 (D) 12 Same as above
10 Poppet
Cotter Pin
Prevents poppet
from turning (and
loosening from
shaft)
Missing or
broken
1) Valve may loosen and
prevent complete fuel shutoff

I (4) 3 (D) 12 Replace Cotter
Pin
2) FOD from pin prevents
valve closure. Fuel may leak
II (3) 3 (D) 9 Same as above
11 Poppet Shuts off fuel flow Fails open Fuel flow cant be shutoff I (4) 3 (D) 12 1) Pressure test
prior to use
2) Shut off fuel at
source
Cracked or
broken
Fuel flow cant be shutoff I (4) 3 (D) 12 Same as above
SM60427

FAILURE
MODE
RESULT OF FAIL
HAZARD
CATEGORY
HAZARD
PROBABILITY
REAL
HAZARD
INDEX
(RHI)
CORRECTIVE
ACTION
Fails closed Cannot refuel IV (1) 3 (D) 3 Same as above
12 Nose Seal Seals poppet valve
in body
Torn or
broken
Fuel Spray I (4) 3 (D) 12 Replace Nose
Seal
13 Snap Ring Holds Plate onto
Nose Seal
Missing or
broken
Nose seal does not stay
completely in place; minor
fuel leak
II (3) 2 (E) 6 Replace Snap
Ring
Poppet valve may be blocked
from closing
II (3) 2 (E) 6 Shutoff fuel at
source. Aircraft
poppet valve will
prevent backflow
14 Nose Seal
Plate
Attaches Nose Seal
to Nozzle Body
Cracked or
loose
Fuel spray I (4) 3 (D) 12 Pressure test prior
to use
15 Lock Pin (3) Prevents rotation of
nozzle collar
Missing 1 or 2 None IV (1) 3 (E) 3 Replace Lock
Pin(s)
Stuck
retracted (1
or 2)
None IV (1) 3 (E) 3 Same as above
Missing all 3 Loss of nozzle collar interlock.
Can flow fuel without nozzle
attached to aircraft
I (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 I (4) 3 (D) 12 Same as above
Stuck
extended
Cannot attach nozzle to
aircraft
IV (1) 3 (E) 3 Replace Lock Pin
Installed
backwards or
upside down
Cannot assemble nozzle IV (1) 3 (E) 3 Install Correctly
16 Lock Pin
Spring (3)
Keeps Lock Pin
extended
Missing or
broken (1 or
2)
None IV (1) 3 (E) 3 Replace Lock
Spring(s)
Missing or
broken (All 3)
Loss of collar interlock
(depending on orientation of
aircraft receptacle)
Can flow fuel without nozzle
attached to aircraft
17 Index Pin (3) Provides proper
alignment between
nozzle and aircraft
receptacle
Missing 1 or 2 None IV (1) 3 (E) 3 Replace Index Pin
Missing all 3 Difficulty attaching nozzle to
aircraft
IV (1) 3 (E) 3

Same as above
18 Body O-Ring Provides seal
between body and
valve seat
assembly
Missing Fuel Spray I (4) 3 (D) 12 Pressure test prior
to use
Torn or
broken
Fuel leak II (3) 3 (D) 9 Same as above
18
A
Body O-Ring Provides seal
between body and
valve seat
assembly
to use
Torn or
broken
Fuel leak II (3) 3 (D) 9 Same as above
19 Handle
Screw
Holds Crank
Handle in place
Missing or
loose
Handle separates IV (1) 4 (C) 4 Use another
handle
SM60427

FAILURE
MODE
RESULT OF FAIL
HAZARD
CATEGORY
HAZARD
PROBABILITY
REAL
HAZARD
INDEX
(RHI)
CORRECTIVE
ACTION
20 Handle Lock
Washer
Provides bearing
surface for Crank
Handle Screw
Missing or
broken
None IV (1) 3 (D) 3 Replace Lock
Washer
21 Crank
Handle
1) Applies force to
open poppet valve
Bent shaft Difficulty in use (binding) IV (1) 3 (D) 3 Replace Crank
Handle
2) Prevents collar
from rotating
Broken shaft 1) Poppet valve opens;
cannot stop fuel flow
I (4) 3 (D) 12 1) Pressure test
prior to use
2) Shut off fuel at
source
2) Crank handle may come off
and release fuel
Broken
locking lug
Possible to rotate collar while
refueling; nozzle separates;
massive fuel spill
I (4) 3 (D) 12 Prior to refuel,
verify integrity by
attempting to
rotate collar with
handle open and
nozzle attached to
aircraft
28 Washer Provides bearing
surface for Crank
Handle
Missing or
broken
Premature wear between
operating handle and bushing
spacer
IV (1) 3 (D) 3 Replace Washer
29 Lock Wire Locks bushing to
housing
Missing or
broken
Precaution to prevent
premature unthreading of the
bushing
IV (1) 3 (D) 3 Replace Wire
Lock
30 Busing Provides clearance
between nozzle
body and Crank
Handle
Missing or
broken
Worn or
gulled
Non-functional

Fuel leaking
IV (1) 3 (D) 3 Replace Bushing
31 Spacer Retains o-ring Missing or
broken
Fuel leaking IV (1) 3 (D) 3 Replace Spacer
32 O-Ring Provides seal
between crank
shaft and Body
to use
33 Wave
Washer
Provides crankshaft
tension
Missing or
broken
Additional play between
nozzle body and operating
handle
IV (1) 3 (D) 3 Replace Wave
Washer
34 Washer Provides bearing
surface Wave
Washers
Missing or
broken
None IV (1) 3 (D) 3 Replace Washer
35 Gasket Provides seal
between Body and
Bushing
to use
36 Crank Cotter
Pin
Prevents Crank
from separating
from Crank Shaft
Missing or
broken
1) Crank may loosen and
prevent complete fuel shutoff

I (4) 3 (D) 12 Replace Cotter
Pin
37 Crank Connects poppet to
Crank handle
assembly (In-Line
with valve link)
Broken Poppet valve opens; cannot
stop fuel flow
I (4) 3 (D) 12
1) Pressure test
prior to use
2) Shut off fuel at
source
Bent Difficult to open or close valve III (2) 3 (D) 6 Same as above

38 Crank Shaft Connects Poppet
Valve to crank
assembly (in line
with shaft).
Broken Poppet valve fails open;
cannot stop fuel flow
Bent Difficult to open or close valve III (2) 3 (D) 6 Same as above
Installed
backwards
Cannot open valve fully IV (1) 3 (D) 3
39 Body Holds all
components
together
Cracked 1) Fuel leak

2) Difficulty in attaching to
aircraft
I (4)

IV (1)
3 (D)

3 (D)
12

3
1) Pressure test
prior to use
2) Visual
Inspection
40 Access Port
Plug (2)
Provides access for
applying pressure
gauge or other
accessories
Missing Massive fuel spill I (4) 3 (D) 12 Same as above
SM60427

FAILURE
MODE
RESULT OF FAIL
HAZARD
CATEGORY
HAZARD
PROBABILITY
REAL
HAZARD
INDEX
(RHI)
CORRECTIVE
ACTION

12.0 FAILURE MODES AND EFFECTS ANALYSIS HOSE END CONTROL VALVE

12.1 Notes that apply to this analysis:
A. Hazard category, hazard probability, and real hazard index (RHI) are defined herein.
B. Visual inspection means examining the regulator for obvious cracks, damage, and broken lugs, prior to initial
pressurization.
C. Pressure test prior to use means pressurizing the regulator to operating fuel pressure, then removing pressure, prior to
aircraft arrival.
D. Shut off fuel at source will be the first action for any leak. To further improve operating safety, this procedure should be
used for all refueling operations. In addition, fuel flow should be turned on at the source, not at the nozzle.
E. Item numbers referred to in this section are those used in Figure 1.
12.2 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 i ndex; 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 Descriptive word Results
I (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
C. Real Hazard Index (RHI) Matrix - (RHI = Hazard Severity X Probability Level)
SEVERITY
I (4) II (3) III (2) IV (1)
PROBABILITY

A (6) 24 18 12 6
B (5) 20 15 10 5
C (4) 16 12 8 4
D (3) 12 9 6 3
E (2) 8 6 4 2
F (1) 4 3 2 1
General guidelines for required action.
RHI
1-8 No action required.
SM60427

9-12 Special precautions required, investigate redesign.
13-24 Hazardous, redesign necessary or procedural control if redesign is impractical.

12.3 FAILURE MODES AND EFFECTS ANALYSIS (FMEA) Refer to Figure 1 for component numbers mentioned in column one.
FAILURE
MODE
RESULT OF FAIL
HAZARD
SEVERITY
HAZARD
PROBABILITY
REAL
HAZARD
INDEX
(RHI)
CORRECTIVE
ACTION
1 Retaining
Ring
Retain piston
assembly against
spring force.
Broken,
missing or
loose
Unrestrained piston assembly II (3) E (2) 6 Inspect prior
to installation
into system
2 Outer Piston Regulate outlet
pressure.
Broken,
scratched or
nicked
Uncontrolled pressure
regulation, failed to lock-out
III (2) D (3) 6
3 Inner piston Isolate working fluid
from reference
fluid.
Broken,
scratched or
nicked
regulation. Leakage coming out
of vent port
III (2) D (3) 6
4 Screw Holds inner and
outer pistons
together.
Broken,
missing,
loose or
stripped
regulation, failed to lock-out.
Leakage coming out of vent
port
III (2) D (3) 6
5 Stat-o-seal Used in conjunction
with screw (item 4).
Broken Uncontrolled pressure
port
III (2) D (3) 6
6 Spring Provides biasing
value between
reference pressure
and outlet pressure.
Broken Permanent lock-out III (2) E (2) 4
7 Outer Piston
Seal
Isolate outlet from
inlet when unit is
locked out
Broken or
nicked
Failed to lock-out III (2) E (2) 4
8 O-Ring To energize seal
(item 7)
Broken Failed to lock-out III (2) F (1) 2
9 Screw Holds item 11 (seal
retainer) in place
Broken,
missing,
loose or
stripped
port
III (2) D (3) 6
10 Washer Used in conjunction
with item 9 (screw)
Broken No effect IV (1) E (2) 2
11 Seal
Retainer
Retains Inner
piston seals and
spacers
Broken or
loose
port
III (2) E (2) 4 Inspect prior
to installation
into system
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) 6
13 Ball To isolate inlet and
outlet during lock-
out
Broken Failed to lock-out. Failed to
hold locked-out pressure
III (2) F (1) 2
14 Spring Provides biasing
value between
outlet pressure and
inlet pressure
Broken Failed to lock-out III (2) E (2) 4
15 O-Ring To provide sealing
seat for outer piston
(item 2)
Broken Failed to lock-out III (2) D (3) 6
16 Spacer To provide
segregation
between the two
sets of seal/O-ring
(item 17 and 18)
port
III (2) E (2) 4
17 Seal Isolate working fluid
from reference fluid
port
III (2) E (2) 4
(item 17)
port
III (2) E (2) 4
SM60427

FAILURE
MODE
RESULT OF FAIL
HAZARD
SEVERITY
HAZARD
PROBABILITY
REAL
HAZARD
INDEX
(RHI)
CORRECTIVE
ACTION
19 Seal To prevent external
leakage.
Broken External leakage II (3) E (2) 6 Inspect prior
to installation
into system
(item 19)
Broken External leakage II (3) E (2) 6

21 Breather
Assembly
To prevent
atmospheric
contaminants from
entering inner
piston cavity
Missing or
loose
Contamination of inner piston
cavity
IV (1) E (2) 2 Inspect prior
to use
25 Screw
Assembly
To provide
containment for
balls (item 27) and
to prevent external
leakage
Broken or
loose
External leakage II (3) E (2) 6 Inspect prior
to use
26 O-Ring To prevent external
leakage.
Broken External leakage II (3) E (2) 6
27 Ball Bearing To secure
mechanical
connection to
mating part
Broken Damage ball race IV (1) F (1) 1
28 O-Ring To prevent external
leakage.
Broken External leakage II (3) E (2) 6 Inspect prior
to installation
into system
29 Housing
Assembly
House all
components
Cracked External leakage. Total failure I (4) E (2) 8 Inspect prior
to use
29
B
Outer Wear
Ring
Provide harden
bearing surface to
protect aluminum
housing
Broken Exposing aluminum housing
ball bearing race to wear.
III (2) E (2) 4
29
C
Inner Wear
Ring
31
A
Continuity
clip
To provide
electrical continuity
(bonding) to mating
component
Broken No ESD protection II (3) E (2) 6

Aerospace Group
Fluid & Electrical Distribution Division
9650 Jeronimo Road
Irvine, CA 92618
Ph (949) 452-9500
Fax (949) 452-9992
E-mail: groundfueling@eaton.com
Copyright 2013 Eaton
Document No. SM60427
May 2013

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