CLA-VAL 353GF

Coupler Lower Half & Control Head

Maintenance Manual

u CLA-VAL Company www.cla-val.com info@cla-val.com EN-353GF (R-09/2018)

© Copyright CLA-VAL 2018 - Specifications subject to change without notice.
 CLA-VAL 353GF
Coupler Lower Half & Control Head
Maintenance Manual

TABLE OF CONTENTS
Section Page No.
INTRODUCTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.0 . . . . . . . . . . 4

INSTALLATION INSTRUCTIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.0 . . . . . . . . . . 4

Overview:. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.1 . . . . . . . . . . 4
Coupler Outlet Connection to Intake Hose or Pipe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.2 . . . . . . . . . . 4
Connection of Deadman Air and Fuel Sense Lines. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.3 . . . . . . . . . . 4
Connecting and Opening the Coupler on the Hydrant Adapter. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.4 . . . . . . . . . . 4
Bleeding the Fuel Sense Line . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.5 . . . . . . . . . . 4
To Disconnecting the 353GF Coupler from the Hydrant Adapter. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.6 . . . . . . . . . . 5

OPERATION INSTRUCTIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.0 . . . . . . . . . . 5

Theory of Operation: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.1 . . . . . . . . . . 5
Opening and Closing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.2 . . . . . . . . . . 5

INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.0 . . . . . . . . . . 6
The Basics: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.1 . . . . . . . . . . 6
Look for missing parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.2 . . . . . . . . . . 6
Check for Seal Leaks. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.3 . . . . . . . . . . 6
Functional Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.4 . . . . . . . . . . 6

COUPLER LOWER HALF MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.0 . . . . . . . . . . 7

Replacing Seals. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.1 . . . . . . . . . . 7
Seal Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.2 . . . . . . . . . . 7
Remove Nose Seal and related O-rings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.2.1. . . . . . . . . . 7
Remove Crank Shaft Seals. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.2.2. . . . . . . . . . 8
Remove Crank Shaft, Link, Poppet Stem and related hardware. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.2.3. . . . . . . . . . 8
Remove and Replace the Sleeve, Fracture Ring and Lock Pin. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.2.4. . . . . . . . . . 8
Replace Crank Shaft, Link, Poppet Stem and related hardware. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.2.5. . . . . . . . . . 9
Replace Crank Shaft Seal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.2.6. . . . . . . . . 10
Replace Nose Seal and related O-rings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.2.7. . . . . . . . . 10

COUPLER CONTROL HEAD MAINTENANCE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.0 . . . . . . . . . 11

Replacing Seals. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.1 . . . . . . . . . 11
Seal Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.2 . . . . . . . . . 11
Remove and Replace Relief Valve Seals. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.2.1. . . . . . . . . 11
Remove Square Cut Shut-Off Seal and Seal Retainer O-Ring:. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.2.2. . . . . . . . . 12
Remove Inner and Outer Piston Seals. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.2.3. . . . . . . . . 12
Remove Shaft Guide Seal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.2.4. . . . . . . . . 12
Replace Inner and Outer Piston Seals. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.2.5. . . . . . . . . 13
Replace Square Cut Shut-Off Seal and Seal Retainer O-Ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.2.6. . . . . . . . . 13
Replace Relief Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.2.7. . . . . . . . . 14

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Coupler Lower Half & Control Head
Maintenance Manual

POST-REPAIR TESTING:. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.0 . . . . . . . . . 15

Examination Of The Coupler. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.1 . . . . . . . . . 15
Pressure Testing In The Closed Position. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.2 . . . . . . . . . 15
Pressure Testing In The Open Position. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.3 . . . . . . . . . 15

TROUBLESHOOTING:. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.0 . . . . . . . . . 16
Troubleshooting External Leaks. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.1 . . . . . . . . . 16
Leak around the Quick Disconnect:. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.1.1. . . . . . . . . 16
Leak around the Inlet Flange: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.1.2. . . . . . . . . 16
Leak at Vent Hole on the Back of the Body:. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.1.3. . . . . . . . . 16
Troubleshooting Mechanical Problems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.2 . . . . . . . . . 16
Coupler will not shut off – leaks pressure downstream:. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.2.1. . . . . . . . . 16
Fuel found in the Air Deadman port of the Air/Fuel Block:. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.2.2. . . . . . . . . 16
Will not regulate pressure accurately/repeatedly: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.2.3. . . . . . . . . 16

PARTS LIST & EXPLODED VIEW. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.0 . . . . . . . . . 17

Parts List - Coupler Lower Half . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.1 . . . . . . . . . 17
Exploded View - Coupler Lower Half. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.2 . . . . . . . . . 18
Parts List - Coupler Control Head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.3 . . . . . . . . . 19
Exploded View - Coupler Control Head. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.4 . . . . . . . . . 20
Spare Kits List / Special Tools / Torque Conversion Table. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.5 . . . . . . . . . 21

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 CLA-VAL 353GF
Coupler Lower Half & Control Head
Maintenance Manual

1.0 INTRODUCTION
This Maintenance Manual covers the INSTALLATION, OPERATION, INSPECTION and MAINTENANCE of the Cla-Val Model
353GF Pressure Control Coupler, referred from here on as just Coupler. All major subassemblies of the Coupler are covered
by this document. There may be other optional items that are covered in other specific documents. There is a TROUBLE-
SHOOTING section for each major subassembly that contains helpful hints for diagnosing problems.

2.0 INSTALLATION INSTRUCTIONS

2.1 Overview:
• The Cla-Val Model 353GF 3rd Edition Pressure Control Coupler is intended for use on all types of hydrant servicing vehicles
for jet aircraft refueling. It must be supplied with a Deadman signal and a remote, hydraulic Fuel Sense signal (ideally sup-
plied from a Venturi). The Coupler will connect to any hydrant Pit Valve or hydrant Adapter design in compliance with
EI 1584. The outlet of the Coupler can be connected, via the Quick Disconnect, to an intake hose or to a pantograph pipe.
2.2 Coupler Outlet Connection to Intake Hose or Pipe:
• It is suggested that the outlet Quick Disconnect fitting (supplied with the Coupler) be threaded onto the intake hose or pipe
when NOT connected to the Coupler. Use Teflon tape or other suitable sealing material for joining NPT threads, or use the
supplied gasket for joining BSPP threads.
• To remove the Quick Disconnect from the Coupler, use a 5/32 inch Allen wrench to remove the two 10-32 Socket Head
Screws retaining the Lock Plate onto the Sleeve. Remove the Lock Plate. Move the Safety Retaining Ring from the groove
close to the Sleeve to the other groove thereby allowing the Sleeve to slide. Slide the Sleeve away from the Coupler and pull
the Quick Disconnect off. Some turning or twisting motion of the Quick Disconnect may assist in removal.
• After the Quick Disconnect is threaded onto the intake hose or pipe, make certain that the sealing O-ring is in place in the
groove within the Quick Disconnect. Push the Quick Disconnect onto the Coupler with the Sleeve pushed back toward the
intake hose or pipe. Some turning or twisting motion of the Quick Disconnect may assist in connection. When completely
pushed on, slide the Sleeve toward the Coupler. Move the Safety Retaining Ring to the forward, locking groove up against
the Sleeve. Replace the Lock Plate in such a way as to restrain the two legs of the Locking Ring and attach it to the Sleeve
with the two Socket Head Screws.
2.3 Connection of Deadman Air and Fuel Sense Lines:
• The Coupler is equipped with two ¼ inch flared tube fittings (male) for connection of the Deadman and Fuel Sense hos-
es. These two fittings are located on the front of the Air/Fuel Block and are parallel to the outlet of the Control Head. Each
connection port is clearly labeled for easy identification and to prevent cross connection. Each connection port is an SAE
Straight Thread, O-ring Sealed port (7/16-20 UN threads per MS33649-06).
2.4 Connecting and Opening the Coupler on the Hydrant Adapter:
• The Coupler is designed to work on any Pit Valve or Hydrant Adapter that is designed per EI 1584 and will work on any hy-
drant adapter that is mounted vertically, as in a common hydrant pit (rather than horizontally as on a loading rack).
• Remove any dust cap from the Coupler and also from the Hydrant Adapter. Place the Coupler onto to the top of the Hydrant
Adapter. Usually the Coupler Sleeve will fall (by gravity) to connect Coupler to Hydrant Adapter. Push the Sleeve completely
down to complete the connection and to allow for the rotation of the Operating Lever.
• Rotate the Operating Lever counter-clockwise to push the Poppet of the Coupler into the top of the Hydrant Adapter to estab-
lish a flow path.
2.5 Bleeding the Fuel Sense Line:
• To provide for smooth, reliable pressure regulation, air must be purged from the Fuel Sense line and from inner chamber of
the Valve A Bleed Valve is provided on the side of the connection block on the top of the Valve for this purpose
• Apply Deadman pressure so as to allow flow through the Valve.
• With at least 20 psig pressure in the Fuel Sense line (usually indicated as “nozzle pressure”), open the Bleed Valve by
rotating the allen-headed bolt counterclockwise 2 turns. Visually verify that fuel (or a potential fuel/air mix) is flowing out of
the small vent hole on the side of the Bleed Valve. Repeat the Deadman pressure application at least 2 more times to aid in
bleeding all air that might be trapped within the inner chamber of the Valve
• When only fuel is flowing from the vent, should you close the valve by fully tightening the allen-headed bolt

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Coupler Lower Half & Control Head
Maintenance Manual

2.6 To Disconnecting the 353GF Coupler from the Hydrant Adapter:

• Close the Coupler by rotating the Operating Lever clockwise.
• Lift the Sleeve of the Coupler and lift the Coupler off of the Hydrant Adapter.
• Replace the Dust Covers into the inlet of the Coupler and onto the top of the Hydrant Adapter.

3.0 OPERATION INSTRUCTIONS

3.1 Theory of Operation:
• The 353GF Pressure Control Coupler is Deadman operated, direct acting, normally closed pressure regulator and surge
pressure attenuator. It connects only to hydrant pit valves or hydrant pit adapters design in compliance with the EI 1584
specification.
• The 353GF Pressure Control Coupler is an “air/fuel set” regulator. This means that the regulation pressure is adjusted by
changing the Deadman pressure supplied to it.
• The closing time and overshoot are calibrated by the factory prior to shipment. The closing time can be adjusted to meet
particular user requirements.
3.2 Opening and Closing:
• Opening and closing of the Coupler is controlled by a compressed Deadman signal.
• When compressed pressure of at least 35 psig is applied to the corresponding port on the top of the Coupler, then the internal
components will stroke to the open position allowing flow through the Coupler.
• When the compressed pressure is released from the Coupler, then the internal components will stroke closed to stop the flow
or fuel through the Coupler.
• Opening time is controlled by an orifice within the Fuel Sense connection port and cannot be adjusted.

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 CLA-VAL 353GF
Coupler Lower Half & Control Head
Maintenance Manual

4.0 INSPECTION
4.1 THE BASICS:
• A quick visual inspection of the Coupler can be a very effective way of preventing dangerous fuel spillage. Each Coupler
should be inspected at least every 3 months (every quarter) to verify that the Coupler is in operating order.
• When inspecting the Coupler, first look for physical damage that might occur from impact against other items or surfaces.
Significant scrapes or gouges on exterior parts can result in exterior leakage and a personal hazard.
• Any part exhibiting a visual crack of any kind must be replaced immediately.
4.2 LOOK FOR MISSING PARTS:
• Look at the inlet end of the Coupler that connects to the API Adapter. Verify that the Nose Seal is complete and in place. Any
cuts or nicks on the rubber Nose Seal can cause an external fuel leak.
• Verify that all six Hex Nuts and Washers are tight holding the Coupler and the Control Head firmly together.
• Verify that all 12 of the Balls are present in the corresponding holes in the end of the Body and are free to move in and out.
• Verify that the Guard (Bumper) is in place on the Sleeve, that it is firmly located and that it is not badly damaged or cut.
• Look at the outlet end of the Coupler with the Quick Disconnect removed. Verify that there are two Race Rings and that they
have not been significantly worn by the movement of the balls within the Quick Disconnect.
• Verify that the Screw and Washer are in place on the side of the Air/Fuel Block covering the closing time adjustment Set
Screw within the Air/Fuel Block.
• When the Quick Disconnect is attached to the Coupler, the Lobed Snap Ring must be in the second exposed groove (away
from the threaded end) on the Swivel Adapter so as to hold the Sleeve in place. The Snap Ring Lock and the two Socket
Head Cap Screws must be in place to secure the Lobed Snap Ring .
• If the Lobed Snap Ring is missing or is not in the second exposed groove, take the Coupler out of service immediately.
• If the Snap Ring Lock or either of the Socket Head Cap Screws is missing, take the Coupler out of service immediately.
• Verify that the Horseshoe Handles are not badly bent and that the handle sockets of the Body are not cracked. Verify that all
four Hex Head Screws and Washers are tight holding the two Horseshoe Handles firmly in the sockets of the Body.
4.3 CHECK FOR SEAL LEAKS:
• Any fuel leaks from metal surfaces or from seals must be dealt with immediately to insure safe operation.
• Check for leaks from around the Nose Seal. Replace the Nose Seal and the related O-ring if fuel leaks from the Nose Seal
when closed.
• Check for leaks from the Nose Seal when connected to an API Adapter. A cut Nose Seal can cause a leak that can fill up a
hydrant pit with fuel while refueling an aircraft!
• Check for leakage from around the Operating Handle and Crank Shaft and replace the Crank Shaft seals if a leak is detected.
• Check the vent hole on the back of the Body for leakage of air or fuel. Fuel leaks will be easily seen as there will be a wetting
of fuel around and/or below the vent hole. NOTE: A very small amount of fuel in or around the vent hole will be very likely
and acceptable. Air leaks must be detected by covering the vent hole with your finger (with Deadman pressure applied to the
Control Head) to see if pressure builds up within the vent hole. A bubble solution (like window cleaner) can also be used to
check for air escaping from the vent hole. NOTE: A very small amount of air leaking from the vent hole will be very likely and
acceptable. Seal replacement is only required if a vent hole leak is excessive.
• Check for leaks from the Quick Disconnect joint. The Quick Disconnect O-ring may need to be replaced if leakage from the
Quick Disconnect is excessive.
• Also check for leaks around the Quick Disconnect pipe threads.
4.4 FUNCTIONAL INSPECTION:
• Verify that the Lock Pin at the inlet end of the Coupler can easily be depressed and is free to return to the extended position.
• The Sleeve should be free from dirt and grit, and free to travel vertically up and down the Body. Only when the Lock Pin is
depressed, should the Sleeve be able to extend down to connect to the API Adapter.
• The Operating Handle should snap to the Closed position and allow the Sleeve to lock in the upper, disconnected position.
• The Operating Handle should snap to the Open position when attached to an API Adapter. Rotation to the fully open position
should be free and smooth.
• When removing the Quick Disconnect from the outlet of the Coupler, the QD Sleeve must slide freely and show no signs of
binding or galling.
• Ensure the stainless Latching Screw (1-35) is secure and correctly torqued to 39 ft. lbs.
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 CLA-VAL 353GF
Coupler Lower Half & Control Head
Maintenance Manual

• Use the Cla-Val 353GF-3 Coupler Wear Gauge to check the Couplers safety interlock mechanism. Install the Wear Gauge
into the inlet side of the Coupler, with the 3 pins facing inwardly. Extend the Coupler sleeve downwards into the locked position,
and open the poppet. All 3 pins should be visibly protruding above the surface of the gauge. Should any of the pins sit below
the surface of the gauge, this indictaes excessive wear, and the Coupler should be removed from service until overhauled.

5.0 COUPLER LOWER HALF MAINTENANCE

5.1 REPLACING SEALS:
• Each Coupler shall be checked for functionality and leaks at least quarterly. Should any mechanical or performance related
failure be detected, a full overhaul is to be undertaken.
• It is recommended that all rubber seals and cotter pins within the Coupler be replaced at every overhaul.
• Following is a list of all seals, and other components needed to perform the seal replacement, within each Coupler.

ITEM PART NUMBER DESCRIPTION QTY.

1-4 00518B O-RING 1
1-5 200293C BACKUP RING 1
1-6 2828701K BEARING 1
1-8 C7754K HANDLE GRIP 1
1-14 00779K O-RING 1
1-17 20952901J GUARD 1
1-19 01140A O-RING 1
1-24 6799212D COTTER PIN 1
1-31 2827601C NOSE SEAL 1
1-39 00838D O-RING 1

5.2 SEAL REPLACEMENT

You will need:
• A Phillips head screwdriver.
• Torque wrench for 10, 13, 24, 46, 82 in. lbs. and 39 ft. lbs.
• Torque wrench adapter for a Phillips head.
• A 7/16 hex wrench or socket.
• Dental pick or similar O-ring extraction tool.
• A liquid thread locking compound.
• ¼ inch wrench
• Bearing grease.
• Rubber faced hammer.
• Set of Allen wrenches (hex keys).
• An O-Ring lubricant that is specifically formulated for use with rubber O-Rings.
5.2.1 Remove Nose Seal and related O-rings:
Removal:
• Make certain that all fuel is drained from Coupler.
• Extend the Poppet (1-15) by first depressing the Lock Pin (1-33) and sliding the Sleeve (1-18) fully down to the connected
position. Then rotate the Operating Lever (1-7) of the Coupler to extend the Poppet (1-15) for service. Leave the Operating
Lever (1-7) in this open condition and invert the Coupler for easy access to the Nose Seal (1-31) and the other seals.
• Remove the six Phillips Head Screws (1-16).
• Remove the Poppet (1-15) and the O-ring (1-14) from inlet of Coupler.
• Remove the Nose Seal (1-31) and the O-Ring (1-39) and the Wave Washer (1-30) from the Body (1-27).

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5.2.2 Remove Crank Shaft Seals:

Removal:
•R
 ECOMMENDATION: It would be very helpful to have the upper housing of an Hydrant Adapter from a Hydrant Pit Valve or
Pit Adapter to aid in the following steps. Only the upper housing is needed with no internal components. This will make mov-
ing the Sleeve (1-18) and rotating the Operating Lever (1-7) much easier and make a convenient holder for the Coupler during
the following steps. This upper housing is not absolutely necessary to perform these steps, it just makes the job easier.
• Place the Coupler onto the Hydrant Adapter if you have one. Depress the Lock Pin (1-33) and slide the Sleeve (1-18) down
to the “connected” position.
• PARTIALLY rotate the Operating Lever (1-7) toward the “open” position. Rotating it about half way will do. You just need to
relieve the spring load from the Wave Washer (1-30) so that the Crank Shaft (1-22) rotates freely.
• Remove Hex Head Bolt (1-11) that retains the Operating Lever (1-7) subassembly. Remove it and the Lock Washer (1-10)
and Retainer (1-9).
• Pull the Operating Lever (1-7) off of the end of the Crank Shaft (1-22).
• Remove the Bearing (1-6) from the end of the Crank Shaft (1-22). This will give access to the two seals on the Crank Shaft
(1-22).
• Carefully remove the Backup Ring (1-5) and then the O-ring (1-4) from within the exposed cavity. It may be helpful to blow a
jet of compressed shop air onto the other end of the Crank Shaft (1-22) to help in ejecting these seals. If this does not work,
and you are unable to retrieve the Seals, then you will have to remove the Crank Shaft (1-22) from the Body (1-27).
See instructions below in 5.2.3 to remove the Crank Shaft (1-22).
5.2.3 Remove Crank Shaft, Link, Poppet Stem and related hardware:
Removal:
• Remove the Cotter Pin (1-24).
• Remove the Spacer (1-21).
• Remove the Pin (1-23) from the Link (1-1) and the Crank Shaft (1-22).
• Slide the Crank Shaft (1-22) inward within the Body (1-27) and remove it and the Washer (1-25).
• NOTE: Stop here if you are only removing the Crank Shaft (1-22) to get at the seals on the Crank Shaft (1-22).
• Extend the Poppet (1-15) and Poppet Stem (1-13) to expose the Poppet Stem Pin (1-12).
• Remove the Poppet Stem Pin (1-12).
• Remove the Link (1-1) through the top of the Body (1-27).
• Remove the Poppet (1-15) and Poppet Stem (1-13) from the bottom of the Body (1-27).
5.2.4 Remove and Replace the Sleeve, Fracture Ring and Lock Pin:
Removal:
• Invert (turn over) the Coupler and remove the Guard (1-17) from the Sleeve (1-18). There is a small slot on the top edge of
the Guard (1-17) for you to insert a flat blade screwdriver into and pry the Guard (1-17) off of the Sleeve (1-18). If you have a
replacement Guard (1-17), then just cut the Guard (1-17) off.
• Remove the Retaining Ring (1-29) from the Sleeve (1-18) by first removing the 8 Soc. Head Cap Screws (1-38).
• Remove the 4 Soc. Head Cap Screws (1-37) from their location in the side of Body (1-27). They are installed in two locations and
can be accessed through the slots in the Sleeve (1-18). These prevent the Sleeve (1-18) from rotating around the Body (1-27).
• Place the up-side-down Coupler in a large box or flat pan so as to contain the Locking Ball (1-26) and the 12 Balls (1-28)
when they come free. Or, take other precautions so that the balls are not lost.
• While holding the Sleeve (1-18) up, depress the Lock Pin (1-33). While depressed, lower the Sleeve (1-18) downward and
completely off of the Body (1-27). As you do this, all balls will become free to roll away.
• Remove the one Locking Ball (1-26) and the 12 Balls (1-28).
• Lift the Body (1-27) out of the Sleeve (1-18) and set it aside.
• Remove the Fracture Ring (1-34) from within the Sleeve (1-18). Note that there is a small Soc. Head Cap Screw (1-36) on
the inner face of the Sleeve (1-18) to hold the rotational position of the Fracture Ring (1-34).

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• Insert a pin or nail or other suitable shaft through the hole provided near the bottom of the Lock Pin (1-33) as a counter-rota-
tion device.
• Remove the Screw (1-20) from the top of the Lock Pin (1-33).
• Remove the Lock Pin (1-33) and the Spring (1-32).
Re-assembly:
• NOTE: It is recommended that you use bearing or o-ring grease to aid in holding all balls in place during re-assembly. Some
such method is recommended to assure that the balls are not misplaced or dislodged during assembly. The Coupler needs
no lubrication during normal use. The grease is used only as an assembly aid.
• Coat each of Locking Ball (1-26) and Balls (1-28) with grease.
• Place Spring (1-32) onto Lock Pin (1-33) and insert Lock Pin (1-33) up into hole in Body (1-27).
• Insert a pin or nail or other suitable shaft through the hole provided near the bottom of the Lock Pin (1-33) as a counter-rota-
tion device.
• Install Screw (1-20) into Lock Pin (1-33). Torque the Screw (1-20) to 24 in. lbs.
• Place greased Locking Ball (1-26) into hole on the outside of Body (1-27) adjacent to the Lock Pin (1-33).
• Place greased Balls (1-28) into the holes around the bottom of Body (1-27).
• Place the Sleeve (1-18) up-side-down on the work surface. Confirm that the Soc. Head Cap Screw (1-36) is installed in the
threaded hole on the inner face of the Sleeve (1-18).
• Inspect the Fracture Ring (1-34) for cracks or broken ligaments. Find the clocking slot on just one side (top of bottom) of the
ring. Install the Fracture Ring (1-34) down into the Sleeve (1-18) with this clocking slot mating with the clocking Soc. Head
Cap Screw (1-36).
• Hold the up-side-down Body (1-27) above the Sleeve (1-18). Align the Sleeve (1-18) so that the Latching Screw (1-35) is
above the Locking Ball (1-26). Depress the Lock Pin (1-33) and slide the Body (1-27) down into the Sleeve (1-18). Then, lift
the Sleeve (1-18) until the two latch together. When the Sleeve (1-18) is installed onto the Body (1-27), the Locking Ball
(1-26) will engage within the Latching Screw (1-35) to hold the Sleeve (1-18) in the “up” position.
• Align the two slots in the Sleeve (1-18) with the 4 threaded holes in the side of the Body (1-27). Apply thread locking
compound to the 4 Soc. Head Cap Screws (1-37). Install the 4 Soc. Head Cap Screws (1-37) into the two locations on the
Body (1-27). These will be installed through the two slots in the Sleeve (1-18).
• Test the mechanical operation of these components by placing the Coupler onto a Hydrant Adapter. The Sleeve (1-18)
should be free to fall resulting in a positive connection to the Adapter. Raise the Sleeve (1-18). The Sleeve (1-18) should
lock in the raised position by the action of the Locking Ball (1-26) inside the Latching Screw (1-35). If this does not happen,
then the Locking Ball (1-26) is likely that the Locking Ball (1-26) fell from the Body (1-27) during assembly.
• Install the Retaining Ring (1-29) into the groove within the lower end of the Sleeve (1-18) using the 8 Soc. Head Cap Screws
(1-38). Torque these to 46 in. lbs.
• Warm up the Guard (1-17) (bumper ring) to help with installation onto the Sleeve (1-18). This can either be done in boiling
water or by using a microwave oven for no more than 30 seconds. Us a rubber faced hammer to aid in forcing the Guard
(1-17) onto the Sleeve (1-18).
5.2.5 Replace Crank Shaft, Link, Poppet Stem and related hardware:
Re-assembly:
• Place Washer (1-25) onto Crank Shaft (1-22).
• Place Crank Shaft (1-22) into the guide hole of the Body (1-27) from within the Body (1-27).
• Insert the Link (1-1) down into the guide hole for the Poppet Stem (1-13) so that the small hole of the Link (1-1) is exposed.
• Position the Poppet Stem (1-13) so that the Link (1-1) is in the slot of the Poppet Stem (1-13) and the holes in each are
aligned (visible from the bottom of the Body (1-27)).
• Insert the Poppet Stem Pin (1-12) into the hole of the Poppet Stem (1-13) and through the Link (1-1).
• Pull up the Link (1-1) until the upper hole of the Link (1-1) is aligned with the hole in the Crank Shaft (1-22). You will have to
rotate the Crank Shaft (1-22) to aid in aligning these two holes.

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• NOTE: The stop lug on the inner face of the Crank Shaft (1-22) must be positioned to impact the Link (1-1) under the radius
or hook of the Link (1-1). If you do not have this orientation correct, then lower the Link (1-1) and Poppet Stem (1-13) slightly,
rotate them 180°, and perform the previous step again.
• Insert the Pin (1-23) into the holes of the Link (1-1) and the Crank Shaft (1-22).
• Place the Spacer (1-21) on the other end of the Pin (1-23).
• Insert a new Cotter Pin (1-24) into the holes of the Spacer (1-21) and the Pin (1-23) and spread the legs of the Cotter Pin
(1-24) so that it is properly retained.
• Rotate the Crank Shaft (1-22) fully in each direction to check for clear operation.
5.2.6 Replace Crank Shaft Seals:
Re-assembly:
• Lubricate the new O-Ring (1-4) and Backup Ring (1-5).
• With the Crank Shaft (1-22) installed in the Body (1-27), place the O-ring (1-4) onto the Crank Shaft (1-22).
• Place the Backup Ring (1-5) onto the Crank Shaft (1-22).
• Push the Bearing (1-6) onto the Crank Shaft (1-22) so as to push the O-ring (1-4) and Backup Ring (1-5) into the recess with-
in the Body (1-27). The flange of the Bearing (1-6) should be up against the Body (1-27).
• Push the Operating Lever (1-7) onto the Crank Shaft (1-22). The Operating Lever (1-7) can go on 4 different ways. Rotate
the Operating Lever (1-7) to the fully “closed” position. When correctly installed, the flat on the Operating Lever (1-7) will be
on the bottom, parallel to the top of the Sleeve (1-18).
• Place the Lock Washer (1-10) and then the Retainer (1-9) onto the Hex Head Bolt (1-11).
• Install the Hex Head Bolt (1-11) (with the Lock Washer (1-10) and the Retainer (1-9)) into the end of the Crank Shaft (1-22).
• Torque the Hex Head Bolt (1-11) to 82 in. lbs.
5.2.7 Replace Nose Seal and related O-rings:
Re-assembly:
• Lubricate the new O-Ring (1-14) and O-Ring (1-39).
• Carefully install O-Ring (1-39) into the groove on the outside of the Nose Seal (1-31).
• Place O-ring (1-14) into the recess of the Poppet (1-15).
• Make certain that the Wave Washer (1-30) is in the recess of the Body (1-27) where the Nose Seal (1-31) goes. Push Nose
Seal (1-31) into the cavity of the Body (1-27) until it stops against the Wave Washer (1-30).
• Carefully place the Poppet (1-15) and the O-ring (1-14) onto the Poppet Stem (1-13) and align the six holes.
• Re-install the six Phillips Head Screws (1-16) to attach the Poppet (1-15) onto the Poppet Stem (1-13). Torque each of Phil-
lips Head Screws (1-16) to 13 in. lbs.
• Rotate the Operating Lever (1-7) of the Coupler to close the Poppet (1-15), thereby compressing the Nose Seal (1-31) into
the Body (1-27).
• Slide/lift the Sleeve (1-18) back to the closed, retracted position. Verify that the Lock Pin (1-33) automatically extends. Also
verify that the Sleeve (1-18) cannot extend without first depressing the Lock Pin (1-33).

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6.0 COUPLER CONTROL HEAD MAINTENANCE

6.1 REPLACING SEALS:
• Each Control Head shall be checked for functionality and leaks quartely. Should any mechanical or performance related
failure be detected, a full overhaul is to be undertaken.
• It is recommended that all rubber seals within the Control Head are replaced at every overhaul.
• Following is a list of all seals, and other components needed to perform the seal replacement, within each Control Head.

ITEM PART NUMBER DESCRIPTION QTY.

2-3 00708J O-RING 1
2-4 71904-05G O-RING 1
2-9 209986-03C INNER PISTON SEAL 2
2-10 00733G O-RING 1
2-15 00746J O-RING 1
2-19 201243B SQUARE CUT RING 1
2-20 00783B O-RING 1
2-21 201247-01H SHAFT GUIDE SEAL 1
2-22 00748E O-RING 1
2-27 209986-01E OUTER PISTON SEAL 1

6.2 SEAL REPLACEMENT:

You will need:
• An 11/16 inch Crow-Foot (or other suitable type) wrench.
• A 5/32 hex key (Allen wrench).
• A 3/8 inch wrench.
• Pressure Control Coupler Seal Installation Tool, part number 208996-01E
• Torque wrench for 13, 22 in. lbs. and 12, 16, 30 ft. lbs.
• A liquid thread locking compound.
• An O-Ring lubricant that is specifically formulated for use with rubber O-Rings.
• Gloves with non-slip surface to grip metal parts.
6.2.1 Remove and Replace Relief Valve Seals:
Removal:
• Invert the Control Head and remove the Relief Valve subassembly by turning the Relief Valve Housing (2-5) counterclockwise.
• Clamp the Relief Valve Guide (2-7) in a bench vise and un-screw the Relief Valve Stem (2-2). NOTE: These parts are spring
loaded. Take proper precaution to contain the spring force when disassembling these parts.
• Remove O-ring (2-4) from Relief Valve Housing (2-5).
• Remove O-Ring (2-3) from the recess under the hex head of Relief Valve Stem (2-2).
Re-assembly:
• Lubricate O-Ring (2-3) and O-ring (2-4).
• Place O-Ring (2-3) onto the shaft of, and under the hex head of, Relief Valve Stem (2-2).
• Carefully install O-ring (2-4) onto Relief Valve Housing (2-5) taking care to not damage or cut the O-ring (2-4).
• Apply thread locking compound to the threads inside of Relief Valve Guide (2-7).
• Loosely re-assemble all components.
• Clamping the Relief Valve Guide (2-7) in a bench vise, apply a force to compress Relief Valve Spring (2-6) so that Relief
Valve Stem (2-2) can be threaded into the Relief Valve Guide (2-7).
• Torque the Relief Valve Stem (2-2) to 11 in. lbs.
• Place part in a clean protected area until needed for re-assembly.

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6.2.2 Remove Square Cut Shut-Off Seal and Seal Retainer O-Ring:
Removal:
• WARNING: DO NOT LOOSEN HEX JAM NUT (2-13) OR FLEX LOCKNUT (2-12).
• Loosen the four Socket Head Cap Screws (2-25) JUST 2 OR 3 TURNS.
• Blow some compressed shop air into the Deadman port on the Body (2-1) just enough to dislodge the Piston Assembly. The
Deadman port is the one furthest from the outlet of the Coupler. This will ease the extraction of the Piston Assembly from
within the Body (2-1).
• Remove the four Socket Head Cap Screws (2-25) and the four Lock Washers (2-24) from the Seal Retainer (2-23).
• Pull on the fins of the Outer Piston (2-28) to extract the Piston Assembly from the Body (2-1).
• Remove the Square Cut Ring (2-19) and the O-Ring (2-20) from within the Body (2-1) or from the back of the Seal Retainer
(2-23).
• NOTE: The Seal (2-9) may have been pulled from the Seal Spacer (2-11) and might be found on the end of the Inner Piston
(2-16). If so, remove them from the end of the Inner Piston (2-16), apply lubrication to both, and place it into the Seal Spacer
(2-11). The correct orientation is with the spring within the Inner Piston Seal (2-9) visible.
• Place piston assembly in a clean protected area.
6.2.3 Remove Inner and Outer Piston Seals:
Removal:
• Remove the Seal Spacer (2-11) and the O-Ring (2-10), the two Inner Piston Seals (2-9). One Inner Piston Seal (2-9) will be
found within the deep cavity of the Body (2-1).
• Remove the Outer Piston Seal (2-27) from the groove just inside the outlet end of the Body (2-1). Take care to not scratch
the groove.
6.2.4 Remove Shaft Guide Seal:
Removal:
• CAUTION: The following instructions deal with disassembling components under extreme spring load. THIS IS A TWO MAN
JOB. Wear all safety equipment (rubber-faced gloves, eye protection, etc.) and follow instructions accurately. IF YOU DO
NOT FEEL CAPABLE OR COMFORTABLE PERFORMING THIS REPAIR, THEN RETURN THE PRODUCT TO CLA-VAL
FOR SERVICING.
• Using a bench vise, take piston assembly (previously removed in 2.1.2), firmly clamp both Hex Nuts on the Outer-Piston-end
of the Piston Shaft (2-26). Orient the Piston Assembly vertically so that the Inner Piston (2-16) is up and the Outer Piston
(2-28) is down.
• Loosen and remove the Flex Locknut (2-12) from the Inner Piston end of the Piston Assembly.
• Loosen, but DO NOT REMOVE, the HEX JAM NUT (2-13).
• Grip the Inner Piston (2-16) with both hands and push down to feel the spring force exerted by the Piston Spring (2-17).
If necessary, further loosen the Hex Jam Nut (2-13) so that you can get a feel for the amount of force that you must oppose
during disassembly.
• TWO MAN JOB: READ THIS STEP AND UNDERSTAND IT BEFORE ATTEMPTING. With two hands, push down on the
Inner Piston (2-16) to compress the Piston Spring (2-17) and to release the load on the Hex Jam Nut (2-13), and remove the
Hex Jam Nut (2-13), (make note of the Washer (2-14) under the Hex Jam Nut (2-13), but don’t bother removing them yet),
then carefully allow the Inner Piston to rise off of the Piston Shaft (2-26). The free length of the Piston Spring (2-17) is about
12.5 inches. NOTE: The Inner Piston (2-16) should rise up off of the Piston Shaft (2-26) without much resistance, but the
O-Ring (2-15) may cause interference. With some twisting and wiggling, the Inner Piston (2-16) will come free.
• Once you have the Inner Piston (2-16) free, remove the Washer (2-14) and O-Ring (2-15) from the top end of the Inner Piston
(2-16).
• Remove Piston Spring (2-17) from Piston Shaft (2-26).
• Remove Seal Retainer (2-23) and Spring Guide (2-18) from Piston Shaft (2-26).
• Remove Shaft Guide Seal (2-21) and O-Ring (2-22) from Seal Retainer (2-23).

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Re-assembly:
• Lubricate all seals.
• Install O-Ring (2-22) onto the outside of the Shaft Guide Seal (2-21).
• Apply a liberal amount of lubrication to these two parts and push them through the hole in the center of the Seal Retainer
(2-23) from the hollow, inner side. With care and lubrication, the four legs or tabs of the Shaft Guide Seal (2-21) will pop
through the Seal Retainer (2-23) and expand to help hold it in place.
• Carefully push the Seal Retainer (2-23) down onto the Piston Shaft (2-26), taking care to not damage the Shaft Guide Seal
(2-21) on the leading edge of the Piston Shaft (2-26).
• Slide the Spring Guide (2-18) down onto the Piston Shaft (2-26) flange end first.
• Install the Piston Spring (2-17) down onto the Spring Guide (2-18).
• Place the Inner Piston (2-16) onto and over the Piston Spring (2-17).
• Prepare the Hex Jam Nut (2-13), Washer (2-14) and O-Ring (2-15).
• TWO MAN JOB: READ THIS STEP AND UNDERSTAND IT BEFORE ATTEMPTING. With two hands, press the Inner
Piston (2-16) down onto the Piston Shaft (2-26) fully compressing the Piston Spring (2-17) and exposing the threaded end
of the Piston Shaft (2-26) out of the end of the Inner Piston (2-16). While holding down the Inner Piston (2-16), install the
O-Ring (2-15) and the Washer (2-14) down on the Piston Shaft (2-26) as far as possible. Install the Hex Jam Nut (2-13) onto
the Piston Shaft (2-26). AT THE VERY LEAST, make sure that the Hex Jam Nut (2-13) is fully engaged onto the threaded
end of the Piston Shaft (2-26) before releasing the Inner Piston (2-16).
• Torque the Hex Jam Nut (2-13) to 15 ft. lbs.
• Install the Flex Locknut (2-12) onto the Piston Shaft (2-26) and up against the Hex Jam Nut (2-13).
• Torque the Flex Locknut (2-12) to 21 ft. lbs.
6.2.5 Replace Inner and Outer Piston Seals:
Re-assembly:
• Lubricate all seals.
• Push one of the Inner Piston Seals (2-9) into the deep cavity of the Body (2-1) with the exposed spring side of the seal facing
down into the cavity. Do this by inserting the seal into the bottom of the cavity, past the cast port found in the bottom of this
cavity, so that the seal is not damaged by the rough edge of this feature. Push the rest of the seal into place against the
shoulder of the Body (2-1).
• Insert the other Small Piston Seal (2-9) into the mating cavity of the Seal Spacer (2-11) with the spring within the Small Piston
Seal (2-9) visible.
• Insert the O-Ring (2-10) into the deep cavity of the Body (2-1). The O-Ring (2-10) will fit snugly into one of these diameters.
• Carefully insert the Seal Spacer (2-11) (with the assembled seal installed within it) into the cavity of the Body (2-1) and onto
the O-Ring (2-10).
• Carefully install the Outer Piston Seal (2-27) into the groove just inside the outlet end of the Body (2-1) with the spring within
the Large Piston Seal (2-27) facing to the interior of the Body (2-1). Push the Outer Piston Seal (2-27) down into the groove
as much as possible.
• NOTE: To better push the Outer Piston Seal (2-27) down into the O-Ring groove, use a spare Outer Piston (2-28) if available.
Press the spare Outer Piston (2-28) into the installed Outer Piston Seal (2-27) with the chamfered end first, and leave it there
for a few minutes. This will fully compress the seals into the groove and make re-assembly of the Piston Assembly into the
Body (2-1) easier.
6.2.6 Replace Square Cut Shut-Off Seal and Seal Retainer O-Ring:
Re-assembly:
• Apply lubrication to both the new Square Cut Ring (2-19) and the new O-Ring (2-20).
• Place O-Ring (2-20) onto the back of the Seal Retainer (2-23) with sufficient lubrication to hold it in place.
• Install the Square Cut Ring (2-19) into the Body (2-1).
• Liberally lubricate the Inner Piston (2-16), the Outer Piston (2-28), the two Inner Piston Seals (2-9) and the
Outer Piston Seal (2-27).

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• NOTE: The following steps can be difficult to successfully achieve. There is a risk that the Outer Piston Seal (2-27) can be
cut or damaged by the insertion of the Outer Piston (2-28).
• Make certain that the Outer Piston Seal (2-27) is as flush and compressed as possible so that the Outer Piston (2-28) can
easily pass into and through the Outer Piston Seal (2-27).
• Firstly, push the two halves of the 208996-01E Coupler Seal Installation Tool together. Be sure that the two chamfered edges
of the tool mate each other. Gently push the Coupler Seal Installation Tool into the outlet side of the pressure control elbow
until it rests on top of the outer piston seal. NOTE: The chamfered edge of the Coupler Seal Installation Tool should be facing
away from the technician, and facing towards the center of the Coupler when installed.
• Slowly, gently and firmly insert the Piston Assembly into the Body (2-1) and into and through the Seals. NOTE: Beware that
the Outer Piston (2-28) can damage the Outer Piston Seal (2-27) when it is pushed into and through the Outer Piston Seal
(2-27). Take great care in forcing the Outer Piston (2-28) into and through the Outer Piston Seal (2-27). Use a combination
of pushing and rotating the Outer Piston (2-28) to get it safely through the Outer Piston Seal (2-27).
• Once through, visually inspect for any sliced piece of Outer Piston Seal (2-27). If found, remove the Piston Assembly, remove
the damaged Outer Piston Seal (2-27) and replace it with a new one. Repeat the above steps to install the Piston Assembly
into the Body (2-1).
• Before inserting the four Socket Head Cap Screws (2-25) into the Seal Retainer (2-23), rotate the Seal Retainer (2-23) so that
the vent hole is at the bottom, 6 o’clock position so that it can communicate with the mating hole in the Body (2-1).
(Most Seal Retainers (2-23) have 4 vent holes, so this step is not necessary.)
• Insert the four Socket Head Cap Screws (2-25) and the Lock Washers (2-24) through the holes of the Seal Retainer (2-23)
and into the threaded holes in the Body (2-1).
• Using a rotational pattern, hand tighten the Socket Head Cap Screws (2-25) to evenly draw the Seal Retainer (2-23) into and
up against the Body (2-1).
Torque the Socket Head Cap Screws (2-25) to 19 in. lbs.
6.2.7 Replace Relief Valve:
• Screw the Relief Valve (previously serviced in 6.2.1) subassembly into the port within the Body (2-1).
• Torque the Relief Valve Housing (2-5) to 18 ft. lbs.

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Maintenance Manual

7.0 POST-REPAIR TESTING:

7.1 EXAMINATION OF THE COUPLER:
• After every form of service other than simple visual inspection, the Coupler must be evaluated and tested prior to being put
back into service.
• First, using an API adapter mounted on a work bench or other suitable surface, connect the Coupler to the adapter and rotate
the Operating Handle to open the Coupler. There should be no binding, scraping or other interference of this operation.
• Remove the Coupler from the adapter before proceeding to section 7.2.
7.2 PRESSURE TESTING IN THE CLOSED POSITION:
• The tests in this section must be performed and passed BEFORE the tests in section 7.3.
• All pressure tests should be performed using jet fuel or a suitable substitute such as Mil-C-7024 Type II calibration fluid. DO
NOT TEST WITH WATER. Wear appropriate safety gear.
• Place the Coupler on a work bench or other suitable surface for testing. Be prepared to catch or contain any fluid that might
leak from the Coupler during testing.
• Install a suitable plug into the outlet threads of the Quick Disconnect end of the Coupler. This plug must have two small ports,
one for filling the Coupler with test fluid and one for the removal of air from within the Coupler. All the valves and/or fittings
associated with these two ports must be strong enough to contain 305 psig.
• Apply at least 40 but not more than 100 psig of pressure into the “AIR/FUEL” port on the Air/Fuel Block. Fill the Coupler with
test fluid. Remove as much air from the Coupler as possible.
• With Deadman pressure on, and the Coupler Operating Lever in the CLOSED position, pressurize the Coupler to 4 to 6 psig.
Hold this pressure for one minute. After one minute, examine the Coupler for leakage. If ANY wetness is observed, the Cou-
pler must not be used until the condition is corrected.
• If the previous test is passed with no leakage, pressurize the Coupler to 175 to 185 psig. Hold this pressure for one minute.
After one minute, examine the Coupler for leakage. If ANY wetness is observed, the Coupler must not be used until the
condition is corrected.
7.3 PRESSURE TESTING IN THE OPEN POSITION:
• The tests in this section must be performed ONLY AFTER the tests in section 7.2.
• All pressure tests should be performed using jet fuel or a suitable substitute such as Mil-C-7024 Type II calibration fluid. DO
NOT TEST WITH WATER. Wear appropriate safety gear.
• Connect the Coupler to an adapter and open the Coupler by rotating the Operating Handle to the fully OPEN position. Be
prepared to catch or contain any fluid that might leak from the Coupler during testing.
• With Deadman pressure on, pressurize the Coupler and adapter to 4 to 6 psig. Hold this pressure for one minute. After one
minute, examine the Coupler for leakage. If ANY wetness is observed, the Coupler must not be used until the condition is
corrected.
• If the previous test is passed with no leakage, pressurize the Coupler and adapter to 295 to 305 psig. Hold this pressure for
one minute. After one minute, examine the Coupler for leakage. If ANY wetness is observed, the Coupler must not be used
until the condition is corrected.

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Coupler Lower Half & Control Head
Maintenance Manual

8.0 TROUBLESHOOTING:
8.1 TROUBLESHOOTING EXTERNAL LEAKS (Why is there a leak at this location?):
8.1.1 Leak around the Quick Disconnect:
• One O-Ring seals this QD joint. It can be found inside the female half of the QD. If the QD leaks under any pressure, inspect
and replace this seal. Refer to the Maintenance Manual for that subassembly for detailed information and part numbers.
8.1.2 Leak around the Inlet Flange:
• The inlet flange to the Control Head is bolted to the API Coupler Lower Half.  One static O-Ring seals this joint.  If the flanged
joint leaks under any pressure, inspect and replace this seal  (1-19) and torque the nuts holding the control head and lower
half together to 171 in. lbs. It is also recommended that this same seal (1-19) is replaced at every overhaul.
8.1.3 Leak at Vent Hole on the Back of the Body:
• Two things can leak out of the small vent port on the back of the Body. One is fuel and the other is air. This vent port is
sealed by Teflon seals that will leak to a very small extent even when new. So, a small amount of wetting in and around the
hole, or a small amount of air escaping out of the hole, is normal. If the leakage grows greater, then both of the Teflon seals
within the Body that seal against the Inner Piston must be changed. Refer to the instructions in section 6.2.5 to change these
seals.
8.2 TROUBLESHOOTING MECHANICAL PROBLEMS (Why doesn’t this part work right?):
8.2.1 Coupler will not shut off – leaks pressure downstream:
• Three seals prevent upstream pressure from leaking downstream when the Deadman pressure is at zero and the Coupler
lower half Operating Lever is set in the Open position. They are the Square Cut Ring, the Outer Piston Cap Seal, and the
Relief Valve Stem O-Ring. Refer to the instructions in sections 6.2.1 - 6.2.6 to change these seals.
8.2.2 Fuel found in the Air Deadman port of the Air/Fuel Block:
• Fuel leaking into the Deadman air system is a very serious matter. If not corrected, fuel can, in some cases, find its way into
the air break system on a refueling vehicle. The source of the fuel leak into the compressed air system must be identified and
corrected as soon as possible. One seal in the Control Head, the O-Ring located on the flat end of the Inner Piston, is the
only direct seal between the Fuel and Air chambers of the Control Head. Refer to the instructions in section 6.2.4 to change
this seal.
8.2.3 Will not regulate pressure accurately/repeatedly:
• The Control Head is an “air/fuel-set” pressure regulator. That means that the regulation set point is adjustable by adjusting
the Deadman pressure supplied to the Coupler. If pressure regulation is not repeatable, it may be because of a failure of the
Shaft Guide Seal. To check for this, remove the outlet quick disconnect fitting to expose the outlet end of the Coupler. Follow
all safety precautions and apply pressurized fuel to the “FUEL” port on the Air/Fuel Block. Start with very low pressure at first.
Visually check for fuel leaking from around the Piston Shaft where it sticks through the Seal Retainer. Gradually increase
pressure to about 50 or 60 psig. If a leak is detected through the Shaft Guide Seal, then refer to the instructions in section
6.2.4 to change this seal.

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Maintenance Manual

9.0 PARTS LIST & EXPLODED VIEW

9.1 Parts List - Coupler Lower Half

Bubble Number Part Number Description Quantity Torque Value

1 2828301J Link 1
2 4287807E Stud 2
3 4287802F Stud 4
4 00518B O-Ring 1
5 200293C Back-Up Ring 1
6 2828701K Bearing 1
7 2828601B Operating Lever 1
8 C7754K Hand Grip 1
9 2828401G Retainer 1
10 6758405C Lock Washer 1
11 21000705D Hex Head Bolt 1 82 in. lbs.
12 2829001D Poppet Stem Pin 1
13 2827901G Poppet Stem 1
14 00779K O-Ring 1
15 2828001E Poppet 1
16 1121701F Screw 6 13 in. lbs.
17 20952901J Guard 1
18 20933001H Sleeve 1
19 01140A O-Ring 1
20 20027501D Screw 1 24 in. lbs.
21 20087401J Spacer 1
22 2828901F Crank Shaft 1
23 20087301G Pin 1
24 6799212D Cotter Pin 1
25 7198840G Washer 1
26 9029005K Locking Ball 1
27 20836001C Coupler Body 1
28 9029010H Ball 12
29 20933101G Retaining Ring 1
30 20027701B Wave Washer 1
31 2827601C Nose Seal 1
32 20027901K Spring 1
33 2829101B Lock Pin 1
34 20932501E Fracture Ring 1
35 20941801C Latching Screw 1 39 ft. lbs.
36 21062903D Socket Head Cap Screw 1 10 in. lbs.
37 6795109F Socket Head Cap Screw 4 13 in. lbs.
38 6795419J Socket Head Cap Screw 8 46 in. lbs.
39 00838D O-Ring 1

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Maintenance Manual

9.2 Exploded View - Coupler Lower Half (figure-1)

35 18

34
19
36
20

2 1
3
21 24 25 9 10
23
5
4 6
11
22
26 8
37
28 27 32 7

33
29

38

17
30
31
39

13 12

15 14

16 209528-EXP-C

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Maintenance Manual

9.3 Parts List - Coupler Control Head

Bubble Number Part Number Description Quantity Torque Value

1 201227-01A Upper Body 1
2 21208901E Relief Valve Stem 1 13 in. lbs.
3 00708J O-Ring 1
4 71904-05G O-Ring 1
5 21208801F Relief Valve Housing 1 30 ft. lbs.
6 90292-21A Relief Valve Spring 1
7 201242-01B Relief Valve Guide 1 13 in. lbs.
8 67847-64A Plug 1 12 ft. lbs.
9 209986-03C Inner Piston Seal 2
10 00733G O-Ring 1
11 201229-01J Seal Spacer 1
12 60761E Flex Lock Nut 2 16 ft. lbs.
13 67802-06G Hex Jam Nut 2 16 ft. lbs.
14 71988-21G Washer 1
15 00746J O-Ring 1
16 201239-01G Inner Piston 1
17 201232-01D Piston Spring 1
18 201238-01K Spring Guide 1
19 201243B Square Cut Ring 1
20 00783B O-Ring 1
21 201247-01H Shaft Guide Seal 1
22 00748B O-Ring 1
23 201231-01E Seal Retainer 1
24 67584-03H Lock Washer 4
25 67953-13D Socket Head Cap Screw 4 22 in. lbs.
26 201234-01B Piston Shaft 1 16 ft. lbs.
27 209986-01E Outer Piston Seal 1
28 201245-01J Outer Piston 1
29 68124-04K Washer 1
30 29641-01E Race Ring 2

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Coupler Lower Half & Control Head
Maintenance Manual

9.4 Exploded View - Coupler Control Head (figure-2)

12
30

13

30
29

26
28

22 23 27

25

21
24

19 20

16 17 18

12 15
13

14
9
11
10

8 9

1 2 3 4 5 6 7

201225-EXP-P

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Maintenance Manual

9.5
Spare Kits List

Kit Part Number Description Includes Bubble Numbers

1-4, 1-5, 1-6, 1-8, 1-14, 1-17,
202139-12C Rebuild Kit, Lower Half (4th Edition)
1-19, 1-24, 1-31, 1-39
1-19, 2-3, 2-4, 2-9, 2-10, 2-15, 2-19,
202139-10E Rebuild Kit, 353GF Upper Half
2-20, 2-21, 2-22, 2-27, PB-12
1-4, 1-14, 1-39, 1-19, 1-5, 1-17, 1-31, 1-24, 2-3, 2-4, 2-9,
202139-15K Rebuild Kit, 353GF Complete
2-10, 2-15, 2-19, 2-20, 2-21, 2-22, 2-27, PB-12, QD-2
274982-85B Rebuild Kit, Nose Seal 1-14, 1-31, 1-39

Special Tools

Tool Part Number Description

210492-01K 3 Edition Coupler Wear Gauge
rd

208996-01E Pressure Control Coupler Seal Install Tool

Torque Conversion Table

Bubble Number Part Number Description Torque in. lbs. Torque ft. lbs. Torque Nm
1-11 21000705D Hex Bolt 82 6.83 9.26
1-16 1121701F Screw 13 1.08 1.46
1-20 20027501D Lock Pin 24 2 2.71
1-38 6795419J Cap Screw 46 3.83 5.19
2-5 21208801F Relief Valve Housing 360 30 40.67
2-12 60761E Lock Nut, Flex 192 16 21.69
2-13 67802-06G Nut, Hex Jam 192 16 21.69
2-25 67953-13D Cap Screw 22 1.83 2.48

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 CLA-VAL
GLOBAL HEADQUARTERS
1701 Placentia Avenue
Costa Mesa, CA 92627
Phone: 800-942-6326
Fax: 949-548-5441
E-mail: info@cla-val.com
CLA-VAL EUROPE CLA-VAL PACIFIC
Chemin des Mésanges 1 45 Kennaway Road
CH-1032 Romanel/ Woolston, Christchurch, 8023
Lausanne, Switzerland New Zealand
Phone: 41-21-643-15-55 Phone: 64-39644860
www.cla-val.ch www.cla-valpacific.com
E-mail: cla-val@cla-val.ch E-mail: info@cla-valpacific.com

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