FUEL SYSTEM REPLENISHING 1. General Pressure refueling facilities are provided by a single point adapter located at the right wing leading edge fillet. Provision is also made for gravity refueling through overwing filler caps in each of the integral wing tanks and auxiliary tanks. The forward and aft auxiliary tanks, if installed are filled through the auxiliary tank. Only fuel conforming to the specification listed in Figure 1 shall be used. For calculation of fuel weights refer to Chapter 28. British Canadian American Specific Gravity D. Eng RD 2482 CAN 2 3.23 ASTM 1655/66T, Jet A 0.775 to 0.840 D. Eng RD 2494 CAN 2 3.23 ASTM 1655/66T, Jet A1 0.775 to 0.840 D. Eng RD 2498 3 GP 24 CAN 2.3.22, Grade JP5 0.788 to 0.845 D. Eng RD 2486 CAN 2 3.22 ASTM 1655/66T, Jet B 0.751 to 0.802 CAN 2.3.22, Grade JP4 0.751 to 0.802 D. Eng RD 2453 MIL T 83133, Grade JP8 0.775 to 0.840 Fuel Specifications Figure 1 2. Fuel Anti Icing Additive A. General If necessary, a fuel anti icing additive conforming to Specification MIL I 27686, can be added to fuel in concentrations of 0.10 to 0.15 percent by volume. This additive is not to be used in grade JP4, JP5 and JP8 fuels because they already contain an equivalent additive. Page 1 Nov 02/98
B. Additive Blending When Pressure Refueling Equipment and Material Pneumatic Injector Commercially available When using the Gate Pak Model 2000 B injector installed on the fueling tender, anti icing additive is automatically blended into the fuel in a ratio of 1 gallon of additive per 1000 gallons of fuel. (1) Check that there is an adequate supply of additive in the tank for the amount of fuel being dispensed. (2) Connect the fueling hose to the single point refueling adapter. (3) Check that the calibration valve is closed on the injector panel. (4) Connect an air supply of 75 psig or greater to the air control panel. (5) Open the injector (outlet) stop valve. (6) Open the inlet valve on the injector panel. (7) Open the air supply valve. (8) Check that the air supply pressure at the air control panel is 65 to 70 psig. (9) Refuel as per normal pressure refueling procedure (refer to paragraph 4.B.). (10) On completion of refueling, stop the flow of additive by closing the air supply valve and the injector stop valve. C. Additive Blending When Gravity Refueling DO NOT ALLOW THE CONCENTRATED ADDITIVE TO CONTACT THE INTERIOR OF THE FUEL TANKS OR THE AIRCRAFT PAINTED SURFACES. Equipment and Material Blender Commercially available (1) Attach the blender to the fuel nozzle, ensuring that the discharge tube enters the fuel system. (2) To ensure correct concentration, use one 20 fluid ounce can of additive for every 104 to 260 gallons of fuel dispensed. Page 2
(3) Replenish fuel at a rate of 30 to 60 gpm, simultaneously pressing the trigger of the additive blender. One 20 fluid ounce can completely discharges in approximately 4 minutes. 3. Fuel Fungicide Additive A. General Fungus and other microbial growths can clog the fuel system s filters, fuel lines and valves, and inhibit the fuel quantity indicating system. If the growth continues untreated, corrosion in the fuel system components can occur causing expensive repairs and increased downtime. The existence of fungal growth may be evident by the presence of a dark slimy mass and/or a sulfur odor found inside the fuel system. If no evidence exists but contamination is suspected, check the fuel for fungal growth using the Kit, Microbial Growth Detector GSE Ref. No. 12 10 14. It is recommended to use a fungicide additive such as Biobor JF or Kathon FP 1.5 to sterilize and/or maintain a fuel system free of fungus and other microbial life. Use the additive as per manufacturer s instructions. 4. Refueling/Defueling A. Safety Precautions WARNING: FUEL VAPORS ARE HIGHLY EXPLOSIVE AND CARE MUST BE TAKEN TO PREVENT IGNITION. SAFETY PRECAUTIONS ARE PROVIDED TO PREVENT INJURY TO PERSONNEL AND/OR DAMAGE TO EQUIPMENT, AND TO ALERT PERSONNEL TO THE HARMFUL EFFECTS OF FUEL COMING IN CONTACT WITH EYES AND SKIN AND OF INHALATION OF FUEL VAPORS. (1) Smoking or any kind of open flame is not allowed in the vicinity of the aircraft. (2) Adequate fire extinguishing equipment, and personnel familiar with its use, must be immediately available and standing by at all times. (3) Ensure that the aircraft and the fuel tender are correctly grounded. (4) Ensure that all electrical power is off except the electrical services required for monitoring the fueling operation. (5) Avoid carrying out other work on the aircraft during the fueling operation. Page 3 May 22/2008
(6) Avoid fuel spillage as this greatly increases the fire hazard. If fuel is spilled, all operations in the vicinity must cease until the spill is cleaned up and the area checked safe by fire personnel. (7) Personnel must take every precaution to avoid fuel contacting eyes and skin, inhalation of fuel vapours, and accidental swallowing of fuel. Anyone exposed to these conditions must wash contacted area thoroughly with water and seek medical attention promptly. (8) Use only clean fuel. If the presence of solid contaminants is suspected during gravity refueling at the overwing filling points, reject the fuel. This fuel must not be used. (9) Do not use felt or chamois filters as these materials can contribute to fuel contamination and generate electrostatic charges. (10) Never exceed a 2500 pound differential in the main wing tanks when refueling or defueling. B. Pressure Refueling REFUELING PRESSURE MUST BE 50 ±5 PSI. Maximum fuel capacity can only be achieved with the wings level and the nose 0.5 degree down. The maximum refueling rate for simultaneous refueling of the three tanks is 250 US gal/min at 55 psi and 150 US gal/min at 55 psi for independent refueling of the main tanks. The following are the power requirements and procedures for pressure refueling: (1) Observe the safety precautions detailed in paragraph 4.A.. (2) On aircraft with SB 600 0481 incorporated, use the Level Attitude Indicator (LAI) in the cockpit or on the refuel/defuel control panel to position the aircraft on the ramp. Position the aircraft to obtain the minimum difference from the wings level indication. Each division on the LAI represents a deviation of 15 minutes of arc from level. Full scale deflection represents 1.5 degrees of arc. No provision is made for fore and aft LAIs. On all other aircraft, position the aircraft to obtain the minimum difference from wings level. Page 4 Sep 29/2006
(3) The use of quantity gauges for refueling requires ac power. This can be supplied from the aircraft APU or external ac power supply. (4) Filling the tanks to full capacity requires the use of dc power. Battery must be connected when external dc power is not used. (5) The BATTERY MASTER switch need not be on since the refuel/defuel control panel is powered from the battery direct bus. WARNING: ENSURE THAT THE FUEL TENDER, THE FUELING CONNECTION AND THE AIRCRAFT ARE PROPERLY BONDED AND GROUNDED. (6) Apply power to the aircraft as required. (7) Open the refuel/defuel control panel access door. (8) Release and swing the control panel forward. All switches must be off. (9) Open the pressure refuel/defuel adapter access door. (10) Remove the cap and connect the fuel nozzle to the adapter. (11) Set the POWER switch on the refuel/defuel control panel to ON and check the following: Ensure that the MODE selector switch is set to OFF. (a) (b) (c) The green POWER ON light comes on. The three green vent valve open (VV OPEN) lights are off. The three green shutoff valve closed (SOV CL) lights come on. (12) Set the refueling pressure to 50 ±5 psi. During the refueling operation, the refueling pressure will drop slightly. Do not reset the refueling pressure to 50 ±5 psi. (13) On aircraft with SB 600 0538 incorporated, open the fuel nozzle to pressurize the fuel manifold and check that the three VV OPEN lights remain off. On all other aircraft, open the fuel nozzle to pressurize the fuel manifold and check that the three VV OPEN lights come on. (14) Rotate the MODE selector switch to TEST. Page 5
WARNING: DURING THE TEST MODE, THE SOV CL LIGHT MUST COME ON. IF THIS CONDITION IS NOT MET, DO NOT PROCEED TO REFUEL THE AIRCRAFT UNTIL THE FAULT IS CORRECTED. (15) On aircraft with SB 600 0538 not incorporated, set the tank switches to FUEL and check that all three green SOV CL lights go out and all three amber shutoff valve open (SOV OP) lights come on. After 20 to 30 seconds, check that all three SOV CL lights come on immediately after all three SOV OP lights go out. WARNING: DURING THE TEST MODE, THE SOV CL AND THE VV OPEN LIGHTS MUST COME ON. IF THESE CONDITIONS ARE NOT MET, DO NOT PROCEED TO REFUEL THE AIRCRAFT UNTIL THE FAULT IS CORRECTED. (16) On aircraft with SB 600 0538 incorporated, set the tank switches to FUEL and check that all three green VV OPEN lights come on, all three green SOV CL LIGHTS go out and all three amber shutoff valve open (SOV OP) lights come on. After 20 to 30 seconds, check that all three SOV CL lights come on immediately after all three SOV OP lights go out. (17) If the aircraft wings do not appear level, refuel as follows: If the aircraft wings appear level, proceed to step (18). (a) On aircraft with SB 600 0481 incorporated, identify the high wing as per the LAI and select the AUX tank and low wing tank switches to OFF. On all other aircraft, identify the high wing and select the AUX tank and low wing tank switches to OFF. (b) On aircraft with SB 600 0538 incorporated, rotate the MODE selector switch to FUEL. Check that all three VV OPEN lights go out, the high tank SOV CL light goes out and the SOV OP light comes on. On all other aircraft, rotate the MODE selector switch to FUEL and check that the high tank SOV CL light goes out and the SOV OP light comes on. (c) On aircraft with SB 600 0481 incorporated, when the LAI shows the aircraft level or when the SOV CL light comes on, set the opposite wing tank switch to FUEL and check that the SOV CL light goes out and the SOV OP light comes on. On all other aircraft, when the wings appear level or when the SOV CL light comes on, set the opposite wing tank switch to FUEL and check that the SOV CL light goes out and the SOV OP lights come on. Page 6 Jun 27/2001
(d) Proceed to step (18). MAINTENANCE MANUAL (18) If the aircraft wings appear level, refuel as follows: (a) (b) Set the AUX tank switch to OFF. On aircraft with SB 600 0538 incorporated, rotate the MODE selector switch to FUEL. Check that the three VV OPEN lights go out and the left and right main tanks SOV CL lights go out and the SOV OP lights come on. On all other aircraft, rotate the MODE selector switch to FUEL and check that the left and right main tanks SOV CL lights go out and the SOV OP lights come on. THE AUXILIARY TANK MUST NOT BE REFUELED INDEPENDENTLY UNLESS THE MAIN TANKS HAVE BEEN REFUELED TO FULL CAPACITY. (19) If fuel is required in the auxiliary tank, set the AUX tank switch to FUEL after fuel has been added to both wing tanks. The auxiliary tank can also be refueled simultaneously with the wing tanks. Check that the associated SOV CL light goes out and the SOV OP light comes on. The forward and aft fuselage tanks, if installed, fill faster than the auxiliary tank. This causes a delay in the AUX tank quantity indicator reading since only the auxiliary tank has quantity transmitters. (20) Continue to fill two or three tanks simultaneously until tanks are filled to the required capacity. At full capacity the fuel shutoff valve will close automatically, the associated SOV OP light will go out and the SOV CL light will come one. (21) Select the tank switches to OFF. REMOVE THE NOZZLE FROM THE SINGLE POINT ADAPTER BEFORE SETTING THE ROTARY MODE SWITCH TO OFF TO PREVENT FUEL SPILLING FROM THE VENT VALVE(S). (22) Close the nozzle valve, remove the nozzle from the single point adapter, replace the cap, close and secure the access door and check the following: On aircraft with SB 600 0538 incorporated, The VV OPEN lights should remain off. On all other aircraft, the VV OPEN lights stay on until the manifold pressure bleeds off Ensure that the VV OPEN lights go out before setting the POWER switch to OFF. Page 7
(23) Rotate the MODE selector switch to OFF and select the POWER switch to OFF. (24) Set all the switches to OFF, stow the control panel and close and secure the access door. (25) Disconnect or shut off the electrical power as required. C. Gravity Refueling DO NOT ALLOW THE FUEL NOZZLE TO TOUCH THE TANK BOTTOM. THE NOZZLE MAY BREAK THE PROTECTIVE COATING AND ALLOW THE TANK SKIN TO BECOME CORRODED. IF A SCREENED FUNNEL IS USED, THE NOZZLE MUST BE AT LEAST 1 INCH SHORTER THAN THE DEPTH OF THE TANK UNDER THE GRAVITY FILLER CAP. THE GRAVITY FILLER CAPS ARE ADJUSTED BY THE VENDOR TO MEET LIGHTNING STRIKE REQUIREMENTS. IF THE FILLER CAPS CANNOT BE OPENED BY HAND, AN APPROPRIATE TOOL MAY BE USED TO PRY UP THE HANDLE. THE AUXILIARY TANK MUST NOT BE REFUELED INDEPENDENTLY UNLESS THE MAIN TANKS HAVE BEEN REFUELED. (1) Observe the safety precautions detailed in paragraph 4.A.. (2) Electrically ground the fuel nozzle and remove the gravity filler cap of the applicable tank. Insert the fuel nozzle and fill the tank with the required amount of fuel. If the tanks are not being filled to capacity, ac power is required on the aircraft to operate the fuel quantity gauges to monitor the amount of fuel in each tank. (3) When the tank is filled to capacity or desired level, remove the nozzle, secure the filler cap and disconnect the nozzle ground. (4) Repeat the procedures for each tank to be refueled. D. Suction Defueling DURING DEFUELING DO NOT EXCEED 8 PSI AS DAMAGE MAY RESULT TO THE FUELING MANIFOLD. IF THIS DEFUELING PRESSURE IS EXCEEDED, THE DEFUELING HOSE WILL PROBABLY COLLAPSE. Equipment and Material Defueling adapter Commercially available (1) Observe the safety precautions detailed in paragraph 4.A.. Page 8
(2) Apply external dc power or use aircraft internal power. The use of fuel quantity gauges requires the use of ac power. (3) Open the refuel/defuel control panel access door. (4) Release and swing the refuel/defuel control panel forward. Ensure that all switches are off. (5) Open the pressure refuel/defuel adapter access door and connect the fuel nozzle to the single point adapter. Install the additional defueling adapter if necessary. (6) Set the POWER switch on refuel/defuel control panel to ON. Check that the vent valve open (VV OPEN) lights are off and the three shutoff valve closed (SOV CL) lights are on. (7) Set the rotary MODE switch to DEFUEL and open the nozzle valve on fuel hose. (8) Set the selected tank switches to DEF. Check that the SOV CL lights go out and the SOV OP lights come on. (9) Start defueling. Set the selected tank switch to OFF, as each tank becomes empty, to permit continued defueling of remaining tanks. (10) Set the tank selector switch to OFF when the correct level is reached or when the tank is empty. (11) Close nozzle valve on the fuel hose and set the rotary MODE switch to OFF. Check that the SOV CL light comes on. (12) Set the POWER switch to OFF. Stow the refuel/defuel control panel and secure the access door. (13) Shut off or disconnect power from the aircraft as required. (14) Remove the fuel hose from the single point adapter, secure the cap and close the refuel/defuel access door. Page 9
E. Gravity Defueling WARNING: ENSURE THAT DEFUELING ADAPTER, FUEL CONTAINERS AND FUEL TANKS ARE ELECTRICALLY BONDED AND GROUNDED. GRAVITY DEFUELING MUST BE CARRIED OUT IN OPEN AIR OR IN WELL VENTILATED AREA. Equipment and Material Gravity defueling adapter GSE Ref. No. 28 30 02 (refer to ILLUSTRATED TOOL AND EQUIPMENT MANUAL) Fuel containers (1) Observe the safety precautions detailed in paragraph 4.A.. (2) Position a container under the fuel drain valve. Sufficient space exists under wing to position a container two feet deep. (3) Open the drain valve by removing the valve cover and inserting the defueling adapter into valve receptacle. Open the defueling adapter valve. (4) When fuel quantity in container approaches full, close the defueling adapter valve and cap the container. (5) Repeat the procedure until fuel flow from the fuel drain valve has stopped. If it is necessary to monitor the amount of fuel remaining in the tank during defueling, ac power must be applied to the aircraft to operate the fuel quantity indicating system. (6) Remove the defueling adapter from the drain valve receptacle and install the drain valve cover. (7) If the left and/or right main tank is being defueled, position a 10 gallon container under the water drain valve of the associated collector tank. (8) Using a screwdriver, open the water drain valve. When the fuel flow from the associated collector tank has stopped, close the water drain valve by rotating the valve core to the closed position. Page 10
F. Defueling Using Standby Fuel Pumps The following procedure describes defueling the complete aircraft or the individual main tank. When defueling one main tank only, the auxiliary tank will also be defueled. The pressurized fuel handling kit can be connected to the left or right pylon firewall fitting as necessary. Equipment and Material Fuel drums Commercially available Pressurized fuel handling kit GSE Ref. No. 28 30 03 (refer to ILLUSTRATED TOOL AND EQUIPMENT MANUAL) (1) Observe the safety precautions detailed in paragraph 4.A.. (2) Open and tag the following circuit breakers (refer to Chapter 24): (a) On aircraft 1004 to 1020 LEFT FUEL PUMP and RIGHT FUEL PUMP (b) On aircraft 1021 and subs, L FUEL PUMP and R FUEL PUMP (3) Remove engine pylon access panel 430 BT (440 CB right) (refer to Chapter 6. (4) Disconnect fuel feed line at pylon firewall fitting and install a protective cover on fuel feed line. Place an empty container under fuel feed line to collect any residual fuel. (5) Connect the pressurized fuel handling kit to pylon firewall fitting and torque to 30 to 40 foot pounds. Electrically ground the kit to the aircraft. (6) Position fuel nozzle of the pressurized fuel handling kit in a suitable fuel drum and electrically ground fuel nozzle to fuel drum. Ensure that fuel drum is grounded. (7) Open pressurized fuel handling kit drain valve located at pylon firewall fitting and close drain valve at fuel nozzle. (8) Remove tags and close the following circuit breakers (refer to Chapter 24): Page 11
(a) On aircraft 1004 to 1020, LEFT FUEL PUMP and RIGHT FUEL PUMP (b) On aircraft 1021 and subs, L FUEL PUMP and R FUEL PUMP (9) Apply external ac power (refer to SERVICING) and set GPWR switch on overhead panel to ON. (10) If it is necessary to defuel the complete aircraft, carry out the following: (a) (b) (c) Operate standby fuel pumps by pressing L TANK PUMP or R TANK PUMP ON/INOP switch/light and check that the INOP legends go out and the ON legends come on. Open drain valve at fuel nozzle to allow fuel to drain into fuel drum. When the fuel quantity in fuel drum approaches full, close drain valve at fuel nozzle and cap fuel drum. TO ENSURE ADEQUATE PUMP COOLING AND PREVENT PUMP CAVITATION, STOP DEFUELING THE AIRCRAFT WHEN FUEL QUANTITY DECREASES TO A MINIMUM OF 50 POUNDS OF FUEL IN EACH MAIN TANK. DO NOT EXCEED AN IMBALANCE OF 2500 POUNDS OF FUEL BETWEEN THE MAIN TANKS. (d) Repeat steps (10)(b) and (10)(c) leaving a minimum of 50 pounds of fuel in each main tank. If a fuel imbalance of 200 pounds of fuel should occur between the main tanks, open the fuel pump circuit breaker (refer to Chapter 24) associated with the main tank containing less fuel. When the fuel quantities in both main tanks are equal, close the fuel pump circuit breaker. Monitor the amount of fuel remaining in the main tanks on the fuel quantity digital indicators. (e) Press out L TANK PUMP or R TANK PUMP ON/INOP switch/light and check that the ON legends go out and the INOP legends come on. (11) If it is necessary to defuel one main tank only, carry out the following: (a) Position jacks at the jacking points under the wing not being defueled. Extend jacks until contact is made with the jacking pads (refer to Chapter 7). Page 12
(b) (c) (d) (e) (f) Close firewall fuel shutoff valve associated with main tank not being defueled (refer to Chapter 28). Open the fuel pump circuit breaker associated with main tank not being defueled (refer to step (2)). Operate standby fuel pump by pressing L TANK PUMP or R TANK PUMP ON/INOP switch/light. Check that the INOP legend goes out and the ON legend comes on. Open drain valve at fuel nozzle to allow fuel to drain into fuel drum. When the fuel quantity in fuel drum approaches full, close drain valve at fuel nozzle and cap fuel drum. TO ENSURE ADEQUATE PUMP COOLING AND PREVENT PUMP CAVITATION, STOP DEFUELING THE MAIN TANK WHEN FUEL QUANTITY DECREASES TO A MINIMUM OF 50 POUNDS. (g) Repeat steps (11)(e) and (11)(f) leaving a minimum of 50 pounds of fuel in each main tank. (12) Set the GPWR switch on the overhead panel to OFF and remove external ac electrical power. (13) Repeat step (2). (14) Open drain valve at pylon firewall fitting to drain residual fuel contained in the pressurized fuel handling kit. (15) Disconnect the pressurized fuel handling kit from pylon firewall fitting. (16) Remove protective cover from fuel feed line, connect fuel feed line at pylon firewall fitting and torque to 100 to 110 foot pounds. (17) Restore electrical power (refer to Chapter 24). (18) Open firewall fuel shutoff valve (refer to Chapter 28). (19) Gravity defuel the remaining fuel in each tank (refer to paragraph 4.E.). (20) When the aircraft is refueled, press in the L TANK PUMP or R TANK PUMP ON/INOP switch/light and check the connection at pylon firewall fitting for fuel leaks. Press out L TANK PUMP or R TANK PUMP ON/INOP switch/light. (21) Install engine pylon access panel 430 BT (440 CB right) (refer to Chapter 6). Page 13
5. Water Contamination Check A. General Water and/or contaminants must be drained from the fuel tanks at regular intervals as prescribed in the inspection schedule. Fifteen self closing drain valves are installed in the fuel system wherever water or other contaminants can collect. B. Fuel Sampling Equipment and Material Fuel sampler GSE Ref. No. 12X 11 01 (Tronair P/N 07 3006 6900 with #2 Philips head) (refer to PSP 611) (1) Allow the aircraft to stand undisturbed for at least four hours. (2) Open each drain valve in turn by using screwdriver fitting on sampler and depress valve. (3) Allow a quantity of fuel to flow into transparent plastic sampler. (4) Visually check fuel in sampler for water or any other contaminants. If water is present, the demarcation line between water and fuel is readily seen. Page 14 Aug 11/2005