PRESSURE REFUELING - SERVICING

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1 PRESSURE REFUELING - SERVICING TASK Use of Fuel Biocide Additive When Pressure Refueling A. Reference Information REFERENCE DESIGNATION TASK TASK Pressure Refueling Fuel System Safety Precautions B. Tools and Equipment REFERENCE GSE 12C DESIGNATION Fuel Additive Injection System Refer to the Illustrated Tool and Equipment Manual to make sure that you use the correct equipment configuration. C. Consumable Materials REFERENCE DESIGNATION MANUFACTURERS REFERENCE AND/OR SPECIFICATION Fuel Additive, Biocide MIL S 53021A D. Setup (1) Obey all the fuel system safety precautions (TASK ). Page 301 Jul 29/2009

2 E. Procedure WARNING: CAUTION: CAUTION: OBEY THE PRECAUTIONS THAT FOLLOW WHEN YOU USE A FUEL ADDITIVE. FUEL ADDITIVES ARE DANGEROUS BECAUSE THEY CAN BE FLAMMABLE, POISONOUS AND CAN CAUSE INJURY. - USE SAFETY GOGGLES. - PUT ON PROTECTIVE CLOTHING. - DO NOT LET BIOCIDE FUEL ADDITIVE TOUCH YOUR SKIN, EYES, AND MOUTH. - DO THE WORK IN AN AREA THAT HAS A GOOD FLOW OF CLEAN AIR. - DO THE WORK IN AN AREA THAT HAS NO SPARKS, FLAME, OR HOT SURFACES. - OBEY THE MANUFACTURER'S INSTRUCTIONS. - GET MEDICAL AID IF YOU GET THE FUEL ADDITIVE IN YOUR EYES OR MOUTH, OR IF IRRITATION OCCURS. DO NOT PUT A CONCENTRATION OF BIOCIDE IN THE FUEL TANKS. USE THE METERED INJECTION METHOD TO MIX THE BIOCIDE DIRECTLY WITH A FLOW OF FUEL. IF YOU PUT BIOCIDE DIRECTLY IN THE FUEL TANK, SALT PARTICLES CAN OCCUR AND CAN CAUSE DAMAGE. DO NOT LET THE FUEL ADDITIVE TOUCH THE INTERNAL SURFACES OF THE FUEL TANK OR EXTERNAL PAINTED SURFACES. HIGH CONCENTRATIONS OF THE FUEL ADDITIVE CAN CAUSE DAMAGE. (1) For regular maintenance, add the fuel biocide additive at a rate of 135 parts per million (ppm) during pressure refueling (TASK ). FUEL [1] BIOBOR JF ADDITIVE (135 ppm) Pounds (U.S.) (Imp.) Liters Pounds (U.S.) (Imp.) Liters (ml) Page 302 Nov 02/2004

3 FUEL [1] BIOBOR JF ADDITIVE (135 ppm) Pounds (U.S.) (Imp.) Liters Pounds (U.S.) (Imp.) Liters (ml) [1] Do not add to JP4 grade fuel if prepared to MIL T 5624H. This fuel contains a 0.10 to 0.15% (by volume) concentration of the biocide. To make an estimate of the fluid ounces necessary to get a concentration of 135 ppm of the additive, multiply the pounds of fuel by To make an estimate of the milliliters (ml) necessary to get a concentration of 135 ppm of the additive, multiply the kilograms of fuel by (2) For shock treatment, add the fuel biocide additive at a rate of 270 ppm during the pressure refueling (TASK ). FUEL [1] BIOBOR JF ADDITIVE (270 ppm) Pounds (U.S.) (Imp.) Liters Pounds (U.S.) Ounces (Imp.) Liters (ml) [1] Do not add to JP4 grade fuel if prepared to MIL T 5624H. This fuel contains a 0.10 to 0.15% (by volume) concentration of the biocide. Page 303 Nov 02/2004

4 To make an estimate of the fluid ounces necessary to get a concentration of 270 ppm of the additive, multiply the pounds of fuel by To make an estimate of the milliliters (ml) necessary to get a concentration of 270 ppm of the additive, multiply the kilograms of fuel by (3) If possible, let the fuel biocide additive remain in the fuel tanks for a period of 36 to 72 hours. F. Closeout (1) Remove all tools, equipment, and unwanted materials from the work area. Page 304 Jul 28/2004

5 TASK Pressure Refueling A. Reference Information BD 100 AIRCRAFT MAINTENANCE MANUAL PART II REFERENCE TASK TASK TASK TASK TASK TASK TASK TASK TASK Grounding of the Aircraft DESIGNATION Use of Fuel Biocide Additive When Pressure Refueling Use of Fuel Anti Icing Additive When Pressure Refueling Electrical/Electronic Safety Precautions Electrostatic Discharge Safety Precautions Fuel System Safety Precautions Drain Water from the Fuel Tank Operational Test of the Fuel Tank Pressure Relief Valve Operational Test of the Fuel Vent System B. Consumable Materials REFERENCE DESIGNATION MANUFACTURERS REFERENCE AND/OR SPECIFICATION Fuel, Jet (refer to AFM for fuel limitations) JET A JET A 1 JET B JP 4 JP 5 C. Setup (1) Obey all the electrical/electronic safety precautions (TASK ). (2) Obey all the electrostatic discharge safety precautions (TASK ). (3) Obey all the fuel system safety precautions (TASK ). (4) Make sure the aircraft is on level ground. Page 305 Aug 07/2008

6 (5) Drain the water from all water drains (TASK ). WARNING: You can drain the water after you refuel the aircraft. If you do this, wait for a minimum of 30 minutes after refueling to let the water collect at the bottom of the fuel tanks. BEFORE YOU REFUEL/DEFUEL THE AIRCRAFT, MAKE SURE THAT YOU GROUND THE FUEL TENDER, THE AIRCRAFT AND THE FUEL NOZZLE. A STATIC ELECTRICAL SPARK DURING THE PROCEDURE CAN CAUSE AN EXPLOSION OR A FIRE. (6) Ground the aircraft, the fuel tender, and the fuel nozzle (TASK ). (7) Install the main landing gear and nose landing gear wheel chocks. (8) Make sure that there is a minimum of 3 in (7.62 cm) between the wheels and the chocks. This will let the wheels expand while the fuel load increases. (9) On the FUEL control panel, make sure that the conditions are as follows: REFERENCE GRAVITY XFLOW push button annunciator (PBA) XFER PBA L PUMP R PUMP POSITION/INDICATION Not pushed in Not pushed in OFF OFF (10) Open the access doors that follow: ACCESS DESIGNATION 181CR 181DR Refuel/Defuel Door Refuel/Defuel Control Panel Door (11) Do the operational test of the fuel vent system (TASK ). (12) Do the operational test of the fuel tank pressure relief valve (TASK ). Page 306 Aug 07/2008

7 D. Procedure Refer to Figure 301. WARNING: WARNING: BEFORE YOU REFUEL THE AIRCRAFT, MAKE SURE THAT THERE ARE NO PERSONS, MATERIALS OR EQUIPMENT BELOW THE AIRCRAFT. THE WEIGHT OF THE FUEL WILL COMPRESS THE LANDING GEAR AND LOWER THE AIRCRAFT. THIS CAN CAUSE INJURY TO PERSONS AND DAMAGE TO EQUIPMENT. WHEN YOU REFUEL/DEFUEL THE AIRCRAFT (PRESSURE OR GRAVITY), OBEY THE INSTRUCTIONS THAT FOLLOW: - DURING THE REFUELING/DEFUELING PROCEDURE, MAKE SURE THAT THE WEIGHT DIFFERENCE BETWEEN THE LEFT AND RIGHT WING FUEL TANKS IS NOT MORE THAN 250 LB ( KG). - WHEN YOU COMPLETE THE REFUELING/DEFUELING PROCEDURE, MAKE SURE THAT THE WEIGHT DIFFERENCE BETWEEN THE LEFT AND RIGHT WING FUEL TANKS IS NOT MORE THAN 250 LB ( KG). IF THE WEIGHT DIFFERENCE IS MORE THAN THE LIMIT, THE AIRCRAFT CAN MOVE AND CAUSE INJURY TO PERSONS AND DAMAGE TO THE EQUIPMENT. (1) Make sure that there are no persons, materials, or equipment below the aircraft. (2) Monitor the LEFT FUEL QTY and the RIGHT FUEL QTY displays (11). (3) Make sure that the weight difference between the LEFT FUEL QTY and the RIGHT FUEL QTY is not more than 250 lb ( kg). (4) If necessary, add the fuel biocide additive during the pressure refueling (TASK ). (5) If necessary, add the fuel anti icing additive during the pressure refueling (TASK ). (6) Do the automatic pressure refueling as follows: (a) Remove the cover from the refuel/defuel adapter (1). You can carefully put the cover behind the lower hinge of the refuel/defuel door. (b) Connect the fuel nozzle from the fuel tender to the refuel/defuel adapter (1). (c) (d) Pressurize the fueling hose between 30 and 50 psi ( and kpa) maximum. On the refuel/defuel control panel, lift the POWER switch guard. Page 307 Oct 25/2007

8 (e) (f) (g) (h) Set the POWER switch (12) to ON. Make sure that the ON light (2) on the refuel/defuel control panel comes on. Let 10 seconds elapse. Make sure that the SOV CL lights (4) come on. (i) On the refuel/defuel control panel, push and hold the LAMP TEST button (3). (j) All the indication lights on the refuel/defuel control panel come on and each display (10) and (11) indicates 8. (k) Release the LAMP TEST button (3). (l) Indication lights return to the previous condition. (m) Set the fuel selector knob (7) to TEST. (n) (o) (p) (q) (r) On the refuel/defuel control panel, make sure that: SOV indication CL lights (4) go off SOV indication OP lights (5) come on L/R H. LEVEL DETECTORS lights (13) come on SOV indication OP lights (5) go off SOV indication CL lights (4) come on. After approximately five seconds, make sure that: L/R H. LEVEL DETECTORS lights (13) go off SOV indication CL lights (4) stay on. Set the fuel detector knob (7) to FUEL AUTO. Set and hold the INC/DEC toggle switch (9) to INC (increase) or to DEC (decrease) until the necessary REFUEL TOTAL QTY (10) shows. Set the AUTO START toggle switch (8) to ON. If the total selected amount of fuel is less than or equal to the current amount of fuel, the automatic pressure refueling will not begin. (s) Make sure that the applicable SOV OP lights (5) come on. (t) Monitor the LEFT FUEL QTY and the RIGHT FUEL QTY displays (11). Page 308 Oct 25/2007

9 (u) The automatic pressure refueling will stop automatically. The main fill phase stops refueling 200 lb before the target values. The R/D SOV closes for 5 seconds and the top up phase starts automatically after. The time delay is to achieve fuel surface stabilization and to perform a more accurate measurement before the top up phase. (v) Make sure that the LEFT FUEL QTY and the RIGHT FUEL QTY displays (11) each show about half of the REFUEL TOTAL QTY (10). (w) (x) (y) (z) Make sure that the SOV OP lights (5) go off and the SOV CL lights (4) come on. After 10 seconds, set the AUTO START toggle switch (8) to OFF. Set the fuel selector knob (7) to OFF. Set the POWER switch (12) to OFF. (aa) Close the switch guard on the POWER switch (12). (7) Do the manual pressure refueling as follows: (a) Remove the cover from the refuel/defuel adapter (1). You can carefully put the cover behind the lower hinge of the refuel/defuel door. (b) Connect the fuel nozzle from the fuel tender to the refuel/defuel adapter (1). (c) (d) (e) (f) (g) (h) Pressurize the fueling hose between 30 and 50 psi ( and kpa) maximum. On the refuel/defuel control panel, lift the POWER switch guard. Set the POWER switch (12) to ON. Make sure that the ON light (2) on the refuel/defuel control panel comes on. Let 10 seconds elapse. Make sure that the SOV CL lights (4) come on. (i) On the refuel/defuel control panel, push and hold the LAMP TEST button (3). (j) All the indication lights on the refuel/defuel control panel come on and each display (10) and (11) indicates 8. (k) Release the LAMP TEST button (3). (l) Indication lights return to the previous condition. Page 309 Oct 25/2007

10 (m) Set the fuel selector knob (7) to TEST. (n) On the refuel/defuel control panel, make sure that: SOV indication CL lights (4) go off SOV indication OP lights (5) come on L/R H. LEVEL DETECTORS lights (13) come on SOV indication OP lights (5) go off SOV indication CL lights (4) come on. (o) After approximately five seconds, make sure that : L/R H. LEVEL DETECTORS lights (13) go off SOV indication CL lights (4) stay on. (p) (q) (r) (s) (t) Set the fuel selector knob (7) to FUEL MANUAL. Set the applicable SOV switch (6) to ON. When the refueling is complete, set the applicable SOV switch (6) to OFF. Set the fuel selector knob (7) to OFF. Set the POWER switch (12) to OFF. (u) Close the switch guard on the POWER switch (12). (8) Set the fuel pressure on the fuel tender to 0 psi (0 kpa). (9) Disconnect the fuel nozzle from the refuel/defuel adapter (1). (10) Disconnect the fuel nozzle ground from the aircraft grounding point. (11) Install the cap on the refuel/defuel adapter (1). (12) If the fuel possibly contains water contamination, do as follows: (a) After a minimum of 30 minutes, drain the water from the fuel tanks (TASK ). Do this step even if you drained water from the tanks before refueling. E. Closeout (1) Remove all tools, equipment, and unwanted materials from the work area. Page 310 Oct 25/2007

11 (2) Close the access doors that follow: ACCESS DESIGNATION 181CR 181DR Refuel/Defuel Door Refuel/Defuel Control Panel Door Page 311 Oct 25/2007

12 B 1 A A POWER B CMM _001 Pressure Refueling Servicing Figure 301 Page 312 Oct 25/2007

13 TASK Use of Fuel Anti Icing Additive When Pressure Refueling A. Reference Information BD 100 AIRCRAFT MAINTENANCE MANUAL PART II REFERENCE DESIGNATION TASK TASK TASK Pressure Refueling Electrostatic Discharge Safety Precautions Fuel System Safety Precautions B. Tools and Equipment REFERENCE GSE 12C DESIGNATION Fuel Additive Injection System Refer to the Illustrated Tool and Equipment Manual to make sure that you use the correct equipment configuration. C. Consumable Materials REFERENCE DESIGNATION MANUFACTURERS REFERENCE AND/OR SPECIFICATION Anti icing additive MIL DTL MIL DTL I, Anti icing additive GOST I M, Anti icing additive GOST TU TGF, Anti icing additive GOST TGF M, Anti icing additive GOST TU Methyl Cellosolve Acetate Commercially Available D. Setup (1) Obey all the electrostatic discharge safety precautions (TASK ). (2) Obey all the fuel system safety precautions (TASK ). Page 313 Jul 29/2009

14 E. Procedure WARNING: CAUTION: CAUTION: OBEY THE PRECAUTIONS THAT FOLLOW WHEN YOU USE A FUEL ADDITIVE. FUEL ADDITIVES ARE DANGEROUS BECAUSE THEY CAN BE FLAMMABLE, POISONOUS AND CAN CAUSE INJURY. - USE SAFETY GOGGLES. - PUT ON PROTECTIVE CLOTHING. - DO NOT LET BIOCIDE FUEL ADDITIVE TOUCH YOUR SKIN, EYES, AND MOUTH. - DO THE WORK IN AN AREA THAT HAS A GOOD FLOW OF CLEAN AIR. - DO THE WORK IN AN AREA THAT HAS NO SPARKS, FLAME, OR HOT SURFACES. - OBEY THE MANUFACTURER'S INSTRUCTIONS. - GET MEDICAL AID IF YOU GET THE FUEL ADDITIVE IN YOUR EYES OR MOUTH, OR IF IRRITATION OCCURS. DO NOT LET THE FUEL ADDITIVE TOUCH THE INTERNAL SURFACES OF THE FUEL TANK OR EXTERNAL PAINTED SURFACES. HIGH CONCENTRATIONS OF THE FUEL ADDITIVE CAN CAUSE DAMAGE. DO NOT ADD UNMIXED PRIST DIRECTLY INTO THE FUEL TANK. UNMIXED PRIST CAN CAUSE DAMAGE TO THE FUEL TANK COMPONENTS. (1) Add the fuel anti icing additive to the fuel, except for Russian and Ukrainian fuels, at a rate of 0.10 to 0.15% by volume during the pressure refueling (TASK ). Fuel Anti Icing Additive [1] Pounds U.S. Imperial Liters Pounds U.S. Fluid Ounces Milliliters Page 314 Aug 07/2008

15 Fuel Anti Icing Additive [1] Pounds U.S. Imperial Liters Pounds U.S. Fluid Ounces Milliliters [1] Do not add the anti icing additive to JP4, JP5, or JP8 fuels. These fuels contain the additive. To make an estimate of the U.S. gallons of anti icing additive necessary, multiply the U.S. gallons of fuel necessary by 0.10%. (2) Add the fuel anti icing additive to the fuel, for Russian and Ukrainian fuels only, at a rate of 0.10 to 0.20% by volume during the pressure refueling (TASK ). Russian and Ukrainian Fuel Additives Anti Icing Additive Reference Concentration to 0.20% [1] to 0.20% [1] to 0.20% [1] to 0.20% [1] [1] In extreme cold conditions, below 40 C ( 40 F), you can use a concentration up to 0.30% by volume. To make an estimate of the U.S. gallons of anti icing additive necessary, multiply the U.S. gallons of fuel necessary by 0.10%. F. Closeout (1) Remove all tools, equipment, and unwanted materials from the work area. Page 315 Aug 07/2008

GRAVITY REFUELING - SERVICING

GRAVITY REFUELING - SERVICING TASK 620 801 1. Use of Fuel Biocide Additive When Gravity Refueling A. Reference Information REFERENCE DESIGNATION TASK 650 801 TASK 28 00 00 910 801 Gravity Refueling Fuel