01 75paa 2 4 7

NAVAIR 01-75PAA-2-4.
7
1 April 1993 Change 3 - 1 April 2001
TECHNICAL MANUAL
ORGANIZATIONAL MAINTENANCE
AIRCRAFT FUEL SYSTEM
NAVY MODELS P-3A, P-3B AND P-3C AIRCRAFT
N00421-98-D-1339
DISTRIBUTION STATEMENT C. Distribution authorized to U.S. Government agencies and their contractors to protect publications required for official use or for administrative or operational purposes only, determined on 1 April 1993. Other requests for this document shall be referred to Commanding Officer, Naval Air Technical Data and Engineering Service Command, Naval Air Station North Island, P.O. Box 357031, Building 90 Distribution, San Diego, CA 92135-7031. DESTRUCTION NOTICE For unclassified, limited documents, destroy by any method that will prevent disclosure of contents or reconstruction of the document.
Published by Direction of Commander, Naval Air Systems Command
0801LP1011460
NATEC ELECTRONIC MANUAL
NAVAIR 01-75PAA-2-4.7
Change 3 - 1 April 2001 NUMERICAL INDEX OF EFFECTIVE WORK PACKAGES/PAGES List of Current Changes Original 0 . . . . . . . . . . . . . . . . . . . . . . . . . 1 April 1993 (Incl prev inc RACs 1-5) Change 1 . . . . . . . . . . . . . . . . . . . . . . 1 October 1995 RAC 7 . . . . . . . . . . . . . . . . . . . . . . . 27 February 1997 (Incl IRAC 6) RAC 8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Cancelled RAC 9 . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 June 1997 Change 2 . . . . . . . . . . . . . . . . . . . . . . . . . . 1 July 1998 (Incl IRAC 10) Change 3 . . . . . . . . . . . . . . . . . . . . . . . . . 1 April 2001 (Incl IRACs 11 and 12) Page A
Only those work packages/pages assigned to the manual are listed in this index. Insert Change 3, dated 1 April 2001. Dispose of superseded and deleted work packages/pages. Superseded and deleted classified work packages/pages shall be destroyed in accordance with applicable regulations. If changed pages are issued to a work package, insert the changed pages in the applicable work package. The portion of text affected in a changed or revised work package is indicated by change bars or the change symbol R in the outer margin of each column of text. Changes to illustrations are indicated by pointing hands or change bars, as applicable. WP Number Title Page A TPDR HMWS 001 00 002 00 003 00 WP Number 004 00 005 00 006 00 007 00 008 00 009 00
Title
Title System Maintenance Wing Fuel Tank Component Maintenance Center Section Fuel Tank Component Maintenance Fuselage Fuel (Bladder) Cell Maintenance Confined Space (Fuel Tank) Testing Explosion Suppressant Foam Baffle System Maintenance
Numerical Index of Effective Work Packages/Pages List of Technical Publication Deficiency Reports Incorporated Warnings Applicable to Hazardous Materials Alphabetical Index Introduction Description and Principles of Operation
Total Number of pages in this manual is 254 consisting of the following: WP/Page No. Change No. WP/Page No. Change No. WP/Page No. Change No.
Title . . . . . . . . . . . . . . . . . . . . . . . A-B . . . . . . . . . . . . . . . . . . . . . . . . C Blank . . . . . . . . . . . . . . . . . . . . TPDR-1 . . . . . . . . . . . . . . . . . . . . TPDR-2 Blank . . . . . . . . . . . . . . HMWS-1-HMWS-5 . . . . . . . . . . HMWS-6 Blank . . . . . . . . . . . . . 001 00 . . . . . . . . . . . . . . . . . . . . . 1........................ 2 Blank . . . . . . . . . . . . . . . . . . 002 00 . . . . . . . . . . . . . . . . . . . . . 1-10 . . . . . . . . . . . . . . . . . . . . . 003 00 . . . . . . . . . . . . . . . . . . . . . 1........................
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1 . . . . . . . . . . . . . . . . . . . RAC 2-5 . . . . . . . . . . . . . . . . . . . . . . 6 Blank . . . . . . . . . . . . . . . . . . 7........................ 8 Blank . . . . . . . . . . . . . . . . . . 9........................ 10 Blank . . . . . . . . . . . . . . . . . 11 . . . . . . . . . . . . . . . . . . . . . . . 12 Blank . . . . . . . . . . . . . . . . . 13-15 . . . . . . . . . . . . . . . . . . . 16 Blank . . . . . . . . . . . . . . . . . 17-35 . . . . . . . . . . . . . . . . . . . 36 Blank . . . . . . . . . . . . . . . . . 37-48 . . . . . . . . . . . . . . . . . . . 49 . . . . . . . . . . . . . . . . . RAC 50-51 . . . . . . . . . . . . . . . . . . . 52-53 . . . . . . . . . . . . . . RAC 54 Blank . . . . . . . . . . . . RAC 008 00 . . . . . . . . . . . . . . . . . . . . . 1-2 . . . . . . . . . . . . . . . . . . . . . . 3........................ 4 Blank . . . . . . . . . . . . . . . . . . 009 00 . . . . . . . . . . . . . . . . . . . . . 1........................ 2........................ 3 . . . . . . . . . . . . . . . . . . . RAC 4........................ 4A . . . . . . . . . . . . . . . . . RAC 4B Blank . . . . . . . . . . . RAC 5........................ 6 Blank . . . . . . . . . . . . . . . . . .
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THIS PAGE INTENTIONALLY LEFT BLANK.
Change 3 - 1 April 2001 TPDR-1/(TPDR-2 Blank)
LIST OF TECHNICAL PUBLICATION DEFICIENCY REPORTS INCORPORATED ORGANIZATIONAL MAINTENANCE AIRCRAFT FUEL SYSTEM
Identification No./ QA Sequence No. N39785-99-0021 48762--99--0007
Location WP009 00, pgs 1 and 31 WP003 00, pgs 1--2
1 April 1993
HMWS-1
WARNINGS APPLICABLE TO HAZARDOUS MATERIALS

1. INTRODUCTION. 3. Complete warnings for hazardous materials referenced in this manual are identified by use of an icon, nomenclature and specification or part number of the material, and a numeric identifier. The numeric identifiers have been assigned to the hazardous materials in the order of their appearance in the manual. Each hazardous material is assigned only one numeric identifier. Repeated use of a specific hazardous material references the numeric identifier assigned at its initial appearance. The approved icons and their applications are shown in Figure 1. 4. In the text of the manual, the caption warning will not be used for hazardous materials. Such warnings will be identified by an icon and numeric identifier. The material nomenclature will also be provided. The user is directed to refer to the corresponding numeric identifier for the complete warning applicable to the hazardous material as shown in Table 1.
2. Warnings for hazardous materials listed in this manual are designed to warn personnel of hazards associated with such items when they come in contact with them by actual use. Additional information related to hazardous materials is provided in OPNAVINST 5100.23, Navy Occupational Safety and Health (NAVOSH) Program manual, NAVSUPINST 5100.27, Navy Hazardous Material Control Program, and the DOD 6050.5, Hazardous Materials Information System (HMIS) series publications. For each hazardous material used within the Navy, a material safety data sheet (MSDS) is required to be provided and available for review by users. Consult your local safety and health staff concerning any question on hazardous chemicals, MSDSs, personal protective equipment requirements, and appropriate handling and emergency procedures and disposal guidance.
EXPLANATION OF HAZARD SYMBOLS CHEMICAL
HMWS-2
THE SYMBOL OF A DROP OF A LIQUID BURNING A HAND SHOWS A MATERIAL THAT CAUSES BURNS TO HUMAN SKIN OR TISSUE.
EXPLOSION
THIS RAPIDLY EXPANDING SYMBOL SHOWS THAT THE MATERIAL MAY EXPLODE IF SUBJECTED TO HIGH TEMPERATURES, SOURCES OF IGNITION, OR HIGH PRESSURE.
EYE PROTECTION
THE SYMBOL OF A PERSON WEARING GOGGLES SHOWS A MATERIAL THAT CAN INJURE YOUR EYES.
FIRE
THE SYMBOL OF A FIRE SHOWS THAT A MATERIAL CAN IGNITE AND BURN YOU.
POISON
THE SYMBOL OF SKULL AND CROSSBONES SHOWS THAT A MATERIAL IS POISONOUS OR IS A DANGER TO LIFE.
VAPOR HAZARD
THE SYMBOL OF A HUMAN FIGURE IN A CLOUD SHOWS THAT BREATHING THIS MATERIAL CAN PRESENT A HEALTH HAZARD.
Figure 1.
Icons for Hazardous Materials and Examples of Application
Table 1. Hazardous Materials Warnings
Index 1 Material TURBINE FUEL, AVIATION, GRADES JP-4, JP-5, JP-8 MIL-T-5624 (JP-4, JP-5) MIL-T-83133A (JP-8) Warning
HMWS-3
Aviation turbine fuel is flammable, toxic and an irritant. Vapor can form explosive mixture with air. Keep away from heat, sparks and open flames. Dispose of saturated rags or paper properly to avoid spontaneous combustion. Use in well-ventilated area. Ingestion: Do not induce vomiting; get medical attention. Eye contact: Flush with water; get medical attention. Skin contact: Wash with soap and water. Remove clothing wet with aviation turbine fuel and launder before reuse. Inhalation: Remove to fresh air; get medical attention. Wash hands with soap and water after use and before eating, drinking or smoking.
PETROLATUM, VV-L-236
Petrolatum is toxic and heated can emit harmful fumes. Avoid contact with skin, eyes and clothing. Wash hands with soap and water after use.
LUBRIPLATE, NO. 130AA
Lubriplate is toxic and when heated can emit harmful fumes. Avoid contact with skin, eyes and clothing. Wash hands with soap and water after use.
COMPOUND, SEALING, POLYSULFIDE, MIL-S-8802, TYPE II, FOR BRUSH APPLICATION
The base component contains methyl ethyl ketone and toluene solvents. Use in well-ventilated area. Avoid repeated or prolonged breathing of vapor and skin contact. Use rubber gloves and goggles. Skin contact: Apply lanolin-base hand cream. Wash hands with soap and water after use and before eating, drinking or smoking. Consult the Material Safety Data Sheet for additional health and safety information.
Table 1. Hazardous Materials Warnings(Cont)
Index 5 Material SOLVENT, DRY CLEANING, P-D-680, TYPE III Warning
HMWS-4
This high flash point dry cleaning solvent is toxic, a skin irritant and an inhalation hazard. Keep away from heat, sparks and open flames. Do not smoke, eat or drink when using solvent. Use in well-ventilated area. Avoid prolonged breathing of vapor and skin contact. Skin contact may cause defatting and irritation of eyes, nose, throat and skin. Inhalation of high concentration of vapor may cause drowsiness and irritation of respiratory tract, which can cause dermatitis, irritated nose and throat and dizziness. Ingestion will cause gastro-intestinal irritation. Wear approved gloves, goggles, coveralls and respirator. Inhalation: Remove to fresh air if vapor causes drowsiness. Skin contact: Flush with water; remove solvent-saturated clothing. Get medical attention.
SOLVENT, DRY CLEANING, P-D-680, TYPE II
Dry cleaning solvent is flammable, toxic, a skin irritant and an inhalation hazard. Keep away from heat, sparks and open flames. Do not use synthetic cloth for wiping with dry cleaning solvent. Metal containers of solvent shall be grounded to prevent sparking and fires. Do not smoke, eat or drink when using solvent. Use in well-ventilated area. Avoid prolonged breathing of vapor and skin contact, which can cause dermatitis, irritated nose and throat and dizziness. Ingestion will cause gastro-intestinal irritation. Wear approved gloves, goggles, coveralls and respirator. Inhalation: Remove to fresh air if vapor causes dizziness. Skin contact: Flush with water; remove solvent-saturated clothing. Get medical attention.
COMPOUND, SEALING, POLYSULFIDE, FOR AIRCRAFT STRUCTURES, MIL-S-7124
Sealing compound is a safe material to handle when reasonable care is observed. The accelerator is readily absorbed through the skin and also produces harmful vapor. Use in well-ventilated area. Avoid repeated or prolonged breathing of vapor, skin contact and ingestion. Use polyethylene gloves and goggles. Skin contact: Flush with warm water; get medical attention in case of extreme exposure. Ingestion: Get medical attention. Wash hands with soap and water after use and before eating, drinking or smoking. Consult the Material Safety Data Sheet for additional health and safety information.
HMWS-5/(HMWS-6 Blank)
Table 1. Hazardous Materials Warnings (Cont)

Index 8 Material OIL, LUBRICATING, JET ENGINE, MIL-L-6081 Warning Lubricating oil is flammable, toxic and an irritant. Keep away from heat, sparks and open flames. Use in well-ventilated area, especially when exposure to hot oil or mist is possible. Eye contact: Flush with water for 15 minutes; get medical attention. Skin contact: Wash with soap and water. Inhalation: Remove to fresh air; get medical attention. Ingestion: Do not induce vomiting; get medical attention. Wash hands with soap and water after use and before eating, drinking or smoking.
COMPOUND, CORROSION PREVENTIVE, MIL-C-6529
Corrosion preventive compound is flammable, toxic and has harmful vapor. Keep container tightly closed when not in use. Keep away from heat, sparks and open flames. Use in well-ventilated area. Wear chemical splash-proof goggles and gloves. Avoid contact with clothing, eyes and skin. Wash hands thoroughly with soap and water after use.
10
TALC, MIL-T-50036
Talc is an irritant. Avoid eye contact. Eye contact: Flush with water for 15 minutes. Inhalation: Remove to fresh air. Ingestion: Do not induce vomiting; get medical attention. Wash hands with soap and water after use and before eating, drinking or smoking.
11
ADHESIVE, RUBBER, MIL-A-5092
Rubber adhesive is flammable and toxic. Keep product and its vapor away from heat, sparks and open flames. Use in well-ventilated area. Avoid prolonged breathing of vapor. Avoid contact with eyes and skin. Keep container tightly closed when not in use.
1 April 1993
001 00
Page 1/(2 Blank)
ALPHABETICAL INDEX ORGANIZATIONAL MAINTENANCE AIRCRAFT FUEL SYSTEM
Title System Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Center Section Fuel Tank Component Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Confined Space (Fuel Tank) Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Description and Principles of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Explosion Suppressant Foam Baffle System Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fuselage Fuel (Bladder) Cell Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . List of Technical Publication Deficiency Reports Incorporated . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Warnings Applicable to Hazardous Materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Wing Fuel Tank Component Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
WP Number 004 00 006 00 008 00 003 00 009 00 007 00 002 00 TPDR HMWS 005 00
1 April 1993 INTRODUCTION AIRCRAFT FUEL SYSTEM
002 00
Page 1
1.
PURPOSE AND SCOPE.
2. PURPOSE. This manual provides organizational maintenance instructions for aircraft fuel system for the P-3A, P-3B and P-3C weapons system. 3. SCOPE. This manual is divided into work packages (WPs), which are stand-alone procedures that support specific functional tasks. Each WP is maintained as a separate entity. Technical content WPs provided in this manual are: description and principles of operation, system maintenance, wing fuel tank component maintenance, center section fuel tank component maintenance, fuselage fuel (bladder) cell maintenance, explosive gas detector and explosion suppressant foam baffle maintenance. WPs are identified by a five-digit number in the upper right corner of each page. 4. REFERENCE MATERIAL.
applicable technical directives (Table 2), contains a record of technical directives affecting equipment or procedures in this manual, and shall remain in the record during the life-cycle of the manual. 1 0 . R E Q U I S I T I O N I N G A N D A U T O M AT I C D I S T R I B U T I O N O F N AVA I R T E C H N I C A L PUBLICATIONS. 11. Procedures to be used by naval activities and other Department of Defense activities requiring NAVAIR technical manuals are defined in NAVAIR 00-25-100 and NAVAIRINST 5605.5. To automatically receive future changes and revisions to NAVAIR technical manuals, an activity must be established on the Automatic Distribution Requirements List (ADRL) maintained by the Naval Air Technical Services Facility (NAVAIRTECHSERVFAC). To become established on the ADRL, notify your activity central technical publications librarian. If your activity does not have a library, you may establish your automatic distribution requirements by contacting the Commanding Officer, NAVAIRTECHSERVFAC, Attn: ADRL REQUEST, 700 Robbins Avenue, Philadelphia, PA 19111-5097. Annual reconfirmation of these requirements is necessary to remain on automatic distribution. Please use your NAVAIRTECHSERVFAC assigned account number whenever referring to automatic distribution requirements. 12. If additional or replacement copies of this manual are required with no attendant changes in the ADRL, they may be ordered by submitting a DD 1348 requisition directly to the Commanding Officer, Naval Publications and Forms Center, 5801 Tabor Road, Philadelphia, PA 19120-5099. 1 3 . A B B R E V I AT I O N S / S Y M B O L S A N D DEFINITIONS. 14. Table 3 lists abbreviations/symbols and definitions that do not appear in MIL-STD-12.
5. COMPLETE LIST OF REFERENCE MATERIALS. A consolidated list of all reference material listed in each WP in this manual is provided in alphabetical order by publication title and publication number (Table 1). 6. QUALITY ASSURANCE.
7. QUALITY ASSURANCE PROCEDURES. Certain procedures or steps of procedures in this manual are followed by QA in parentheses. These procedures or steps, if improperly performed, will cause equipment or personnel hazards. A quality assurance inspection of each item followed by (QA), in boldface type, shall be performed before proceeding to the next step; unless it can be determined by QA personnel that such an inspection can be performed after completion of the entire procedure. 8. TECHNICAL DIRECTIVES.
9 . HIS TORICA L RECORD OF APP LICAB LE TECHNICAL DIRECTIVES. A historical record of
Table 1. Reference Materials
002 00
Page 2
Title
Publication No.
Aircraft Fuel Cells and Tanks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . NAVAIR 01-1A-35 Aircraft Refueling for Shore Activities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . NAVAIR 06-5-502 Airframe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . NAVAIR 01-75PAA-2-2 Auxiliary Power Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . NAVAIR 01-75PAA-2-4.4 Connector and Wire Repair Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . NAVAIR 01-75PAA-2-15 Connector and Wire Repair Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . NAVAIR 01-75PAA-2-15.1 Corrosion Control for Aircraft Weapons Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . NAVAIR 01-1A-509 Corrosion Control, Cleaning, Painting and Decontamination . . . . . . . . . . . . . . . . . . . . . NAVAIR 01-75PAA-2-2.1 Electrical Power Generation and Distribution . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . NAVAIR 01-75PAC-2-13.1 Explosive Gas Detector Set, PN 72-8001 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . NAVAIR 17-75-63 General Information and Servicing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . NAVAIR 01-75PAA-2-1 Powerplant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . NAVAIR 01-75PAA-2-4.3 Powerplant Quick Engine Change Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . NAVAIR 01-75PAA-2-4.5 Powerplant Related Electrical Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . NAVAIR 01-75PAA-2-30 Powerplant Related Electrical Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . NAVAIR 01-75PAC-2-13.1.2 Powerplant and Related Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . NAVAIR 01-75PAA-2-4 Structural Hardware . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . NAVAIR 01-1A-8 Structural Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . NAVAIR 01-75PAA-3-1 Structural Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . NAVAIR 01-75PAA-3-1.1 Table 2. Type/No. AFC 53 AFC 159 AFC 188 AFC 323 AFC 392 AFC 532 None 6 Jun 64 Date 26 Jun 64 5 Jun 67 2 Mar 70 1 Apr 75 Historical Record of Applicable Technical Directives Title and ECP No. POWERPLANT: Modification of Lower Auxiliary Engine Mount (ECP 189) FUEL SYSTEM: Deletion of Integral Start System Fuel Boost Pump (ECP 515) AIRFRAME: Increased Gross Weight and Fuel Dump Capability (ECP 494) FUEL SYSTEM: Addition of Fueling Caution Decal FUEL SYSTEM: Modification of Fuel Venting (ECP 934R1) FUEL SYSTEM: Addition of Aft Transfer Pump Overboard Drain (ECP 330) FUEL SYSTEM: Installation of Metal Fuel Probes in Lieu of Fiber Glass (VECP 877) Date Inc. 1 Jun 65 1 Apr 68 15 Dec 70 15 Nov 75 15 Jan 81 1 Jun 65 22 May 78 Remarks
Table 3. Abbreviations/Symbols and Definitions Table 4.
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Page 3 Support Equipment Required (Cont) Type Designation/ Part No. CAGE 57A42 Blairdell 1173F AS02 AN/USM-311 NF15-3 80058
Abbreviation/Symbol
Definition
Nomenclature Light, Fuel Cell Inspection Marker, Fuel Resistant Mask, Hose Blower Multimeter Pump, Breathing, Ambient Air Respirator, Air Line Respirator, Cartridge Organic Vapor Retainer, Fuel Drain Mast Screen, Mesh, 1/4 in Set, Explosive Gas Detector Source, Fuel Servicing Spring Stand, Maintenance Tool, Fuel Boost Pump Removal and Installation Tool, Fueling and Transfer Valve Removal and Installation Tool, Pump Removal and Installation Tool, Valve Body Removal and Installation Wrench, Spanner Wrench, Torque, 0 to 150 lb-ins Wrench, Torque, 100 to 750 lb-ins 17.
ADRL Automatic Distribution Requirements List AVGFET Aviation Gas Free Engineering Technician BUNO Bureau Number CAGE Commercial and Government Entity _C Degrees Centigrade _F Degrees Fahrenheit GFE Gas Free Engineer gpm Gallons Per Minute IMRL Individual Material Readiness List lb-ft Pound-feet lb-ins Pound-inches LEL Lower Explosion Limit UNF Unified Fine Thread Series WP Work Package
GGG-M-125/1B, 81348 Type II GG-M-125/6 81348 B-544 72-8001 5812-8 B4A BC65-101 925312-1 36659 51906 98897 36659 36659
15.
SUPPORT EQUIPMENT REQUIRED.
16. Table 4 provides a consolidated list of support equipment required for the tasks in each WP. When an item of support equipment is not available, an approved alternate identified in the activitys Individual Material Readiness List (IMRL) may be substituted. Table 4. Support Equipment Required Type Designation/ Part No. CAGE AF-17-8 MIL-C-14610 NF14-2 DPP-30 ZZ-G-381 GG-G-531 81349 81348 81348
112-493 833739-1
36659 36659
Nomenclature Blower Container, Drying Container, Safety, Fuel 5 gal Coveralls Fan, 12 in Gauge, Feeler Gauge, Force, 0 to 25 lb Gauge, Force, 0 to 25 lb-ins Gloves, Rubber, Industrial Goggles, Industrial and Spectacles Knife, Foam Light, Extension, Explosion-proof
MATERIALS REQUIRED.
18. Table 5 provides a consolidated list of materials required for the tasks in each WP. Table 5. Materials Required Specification/ Part No. MIL-A-5092
GGG-C-746 81348 MIL-F-16377/52
Nomenclature Adhesive, Rubber
Table 5. Materials Required (Cont) Specification/ Part No.
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Page 4 21. Use only precision measuring tools and equipment which have been properly calibrated. A precision tool which has been dropped or otherwise abused may not perform correctly.
Nomenclature
Bag, Opaque Antistatic Plastic MIL-B-81705, Type II Box, Corrugated MIL-B-38721 Brush, Bristle Cloth, Aluminum Oxide Abrasive P-C-451, 180 Grit Cloth, Cleaning CCC-C-46, Type 1, Class 4 Cloth, Low-lint MIL-C-85043, Type II Compound, Corrosion Preventive MIL-C-6529 Compound, Sealing, Polysulfide MIL-S-8784, Type II Compound, Sealing, Polysulfide, MIL-S-8802, Type II for Brush Application Cord, Nylon MIL-C-5040, Type III Extrusions, Aluminum L-Channel Foam, Explosion Suppressant MIL-B-83054-B, (Foam Baffle) Type VI Grid, Expansion Metal J-Slot Ring, 8 in Lockwire MS20995C20 Lockwire MS20995C32 Lubriplate No. 130AA Oil, Lubricating MIL-L-6081 Petrolatum VV-L-236 Sheet Metal, Aluminum, 2024T3 0.032 or 0.040 Sleeving, Anti-chafe, Vinyl, MIL-I-631 Protective, 72 in Solvent, Dry Cleaning P-D-680, Type III or II (Type III preferred) Steel Angle, 1 in Steel Square Tube, 1 in x 10 ft Talc MIL-T-50036 Tape PPP-T-60 Turbine Fuel, Aviation, JP-4 or JP-5 MIL-T-5624 Turbine Fuel, Aviation, JP-8 MIL-T-83133A
2 2 . T O R Q U E W R E N C H A D A P T E R . To r q u e wrench adapters may be used in areas where application of a torque wrench without an adapter is impractical or difficult. Actual torque applied at the adapter with adapter attached shall be calculated (Figure 5). 23. BOLT IDENTIFICATION MARKINGS.
24. Bolts are marked with a code to identify their physical characteristics and contents. Refer to NAVAIR 01-1A-8 for bolt code markings. 25. INTERNAL WRENCHING FASTENERS.
26. A variety of externally threaded, internal wrenching fasteners are used in airframe manufacturing. Some have not, as yet, had a military designation assigned to them. Some examples of the various wrenching recesses are described in the following paragraphs. 27. The Hi-Torque recess is a single, curved-bottom slot, narrower at the center than at the ends. This, and the center dimple, make the recess readily identifiable by its bow tie appearance. The slot sides are undercut, producing an inverted keystone shape in the cross section. 28. The Torq-Set recess is distinctive in appearance. The four driving wings are not centered on the vertical axis of the fastener, but are offset so that the installing side of the wing passes through the axis. Also, there is no taper to the sides of the driving wings. 29. The Frearson recess and the Phillips recess are similar in appearance (both have four driving wings). However, the Frearson recess has squarecut corners at the head surface and the corners of the Phillips recess are slightly chamfered. The slotted or common is the most universally used recess and is distinctive because of its single, flat-bottomed groove or slot. The socket recess is a normal six-sided hexagon (Allen wrench type recess). The Torx recess is distinctive in appearance. The Torx recess has six short driving wings with round corners, similar to the impression of a six-tooth gear or sprocket. The Tri-Wing recess is distinct because of its three driving wings.
19.
TORQUE VALUES.
20. All special torque values are stated in the text of each procedure. For standard torque values on nuts, bolts, studs, screws, piping, and electrical couplings, refer to standard torque tables in Figures 1 through 4.
WRENCH TORQUE IN POUND-INCHES FINE THREAD SERIES STANDARD OR TENSION NUTS BOLT OR SCREW SIZE 10-32 1/4-28 5/16-24 3/8-24 7/16-20 1/2-20 9/16-18 5/8-18 3/4-16 7/8-14 1-14 & 1-12 1 1/8-12 1 1/4-12 PLAIN, SELF-LOCKING AND CASTELLATED NUTS 25-40 70-100 140-225 190-390 450-500 480-690 800-1000 1000-1300 2300-2500 2500-3000 3700-5500 5000-7000 9000-11000 AN310 CASTELLATED NUTS, ALTERNATE VALUES 20-40 50-100 100-225 160-390 450-660 480-840 800-1250 1100-1800 2300-3700 2500-4900 3700-7300 5000-10000 9000-17500 SHEAR NUTS PLAIN, SELF-LOCKING AND CASTELLATED NUTS 12-15 30-40 60-85 95-110 270-300 290-410 480-600 660-780 1300-1500 1500-1800 2200-3800 3000-4200 5400-6600
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Page 5
AN310 CASTELLATED NUTS, ALTERNATE VALUES 12-19 30-48 60-106 95-170 270-390 290-500 480-750 660-1060 1300-2200 1500-2900 2200-4400 3000-6300 5400-10000
AIR FORCE-NAVY AERONAUTICAL DESIGN STANDARD 10064 FITTING INSTALLATION DASH NO. -4 -5 -6 -8 -10 -12 -16 -20 -24 -28 -32 1/4 5/16 3/8 1/2 5/8 3/4 1 1 1/4 1 1/2 1 3/4 2 TUBING OD ALUMINUM ALLOY 40-65 60-80 75-125 150-250 200-350 300-500 500-700 600-900 600-900 STEEL TUBING 135-150 180-200 270-300 450-500 650-700 900-1000 1200-1400 HOSE END FITTINGS 70-120 85-180 100-250 210-420 300-480 500-850 700-1150
FLARED STEEL TUBES WITH ALUMINUM ALLOY FITTINGS TUBE SIZE 1/2 5/8 3/4 1 1 1/4 1 1/2 TORQUE 200-300 350-450 500-600 700-800 900-1000 900-1000
ON ALL ENGINE FURNISHED STUDS OR SCREWS THREAD SIZE 10-32 1/4 5/16 3/8 7/16 1/2 9/16 5/8 TORQUE 60-75 80-85 125-140 275-300 425-450 550-600 825-875 1125-1200
Figure 1.
Table of Standard Torque Values, Bolts and Nuts
NAVAIR 01-75PAA-2-4.7 - THREAD SIZE WRENCH SIZE (INCHES) TORQUE* THREAD SIZE WRENCH SIZE (INCHES)
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Page 6
TORQUE*
NOTE
1. 2. 3. LUBRCATE ALL PIPING PARTS AS SPECIFIED BEFORE TIGHTENING. WHEN TIGHTENING OR LOOSENING HOSE COUPLING NUTS, MAKE SURE THAT THE HOSE NIPPLE DOES NOT TURN ON THE MATING FITTING SEAT. ON BUSHING-TYPE PARTS THAT SEAT METAL-TO METAL OVER A SEAL, USE THE SAME BOTTOMING TORQUE AS FOR FITTINGS WITH LIKE THREAD SIZE. PIPING ASSEMBLIES STEEL COUPLING NUTS ON STEEL FITTINGS: 5/16-24 3/8-24 7/16-20 1/2-20 9/16-18 3/4-16 7/8-14 1 1/16-12 1 5/16-12 1 5/8-12 3/8 7/16 9/16 5/8 11/16 7/8 1 1 1/4 1 1/2 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35-40 . . . . . . . . . . . . . . . . . . . . . . . . . . . 65-100 . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-120 . . . . . . . . . . . . . . . . . . . . . . . . . 150-200 . . . . . . . . . . . . . . . . . . . . . . . . . 200-250 . . . . . . . . . . . . . . . . . . . . . . . . . 325-400 . . . . . . . . . . . . . . . . . . . . . . . . . 475-575 . . . . . . . . . . . . . . . . . . . . . . . . 55-65 lb-ft . . . . . . . . . . . . . . . . . . . . . . . . 60-80 lb-ft . . . . . . . . . . . . . . . . . . . . . 100-125 lb-ft ALUMINUM REDUCER BUSHINGS: 9/16-18 1 5/8-12 1/2-24 57/64-18 5/16-24 3/8-24 7/16-20 1/2-20 9/16-18 3/4-16 7/8-14 1 1/16-12 1 5/16-12 1 5/8-12 1 5/8-12 1 7/8-12 5/16-24 3/8-24 7/16-20 1/2-20 9/16-18 3/4-16 7/8-14 1 1/16-12 13/16 . . . . . . . . . . . . . . . . . . . . . . . . . 100-150 1 7/8 . . . . . . . . . . . . . . . . . . . . . . . . 50-65 lb-ft 9/16 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35-40 1 . . . . . . . . . . . . . . . . . . . . . . . . . 150-200 9/16 5/8 11/16 3/4 13/16 1 1 1/8 1 3/8 1 5/8 1 7/8 1 15/16 2-1/8 9/16 5/8 11/16 3/4 13/16 1 1 1/8 1 3/8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18-25 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-75 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55-80 . . . . . . . . . . . . . . . . . . . . . . . . . . . 75-110 . . . . . . . . . . . . . . . . . . . . . . . . . 100-150 . . . . . . . . . . . . . . . . . . . . . . . . . 200-300 . . . . . . . . . . . . . . . . . . . . . . . . . 300-450 . . . . . . . . . . . . . . . . . . . . . . . . . 420-600 . . . . . . . . . . . . . . . . . . . . . . . . 50-70 lb-ft . . . . . . . . . . . . . . . . . . . . . . . . 65-85 lb-ft . . . . . . . . . . . . . . . . . . . . . . . . 65-85 lb-ft . . . . . . . . . . . . . . . . . . . . . . . . 60-75 lb-ft . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-16 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-40 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-65 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-80 . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-120 . . . . . . . . . . . . . . . . . . . . . . . . . 150-200 . . . . . . . . . . . . . . . . . . . . . . . . . 200-350 . . . . . . . . . . . . . . . . . . . . . . . . . 300-500
PACKING TYPE COUPLING NUTS:
ALUMINUM OR STEEL UNIONS:
STEEL WITH ALUMINUM OR ALUMINUM WITH ALUMINUM COUPLING NUTS ON FITTINGS: 5/16-24 3/8-24 7/16-20 1/2-20 9/16-18 3/4-16 7/8-14 1 1/16-12 1 5/16-12 1 5/8-12 1 7/8-12 3/8 7/16 9/16 5/8 11/16 7/8 1 1 1/4 1 1/2 2 2 1/4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-25 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25-40 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-65 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-80 . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-120 . . . . . . . . . . . . . . . . . . . . . . . . . 150-200 . . . . . . . . . . . . . . . . . . . . . . . . . 200-350 . . . . . . . . . . . . . . . . . . . . . . . . . 300-500 . . . . . . . . . . . . . . . . . . . . . . . . 40-60 lb-ft . . . . . . . . . . . . . . . . . . . . . . . . 50-75 lb-ft . . . . . . . . . . . . . . . . . . . . . . . . 50-75 lb-ft
PLUGS AND BLEEDERS:
ALUMINUM OR STEEL UNIONS AND UNIFIED FINE THREAD SERIES (UNF) LOCKNUTS (PLAIN): 5/16-24 3/8-24 7/16-20 1/2-20 9/16-18 3/4-16 7/8-14 1 1/16-12 1 5/16-12 1 5/8-12 1 5/8-12 1 7/8-12 1 7/8-12 9/16 5/8 11/16 3/4 13/16 1 1 1/8 1 3/8 1 5/8 1 7/8 1 15/16 2 1/8 2 3/16 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18-25 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-75 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55-80 . . . . . . . . . . . . . . . . . . . . . . . . . . . 75-110 . . . . . . . . . . . . . . . . . . . . . . . . . 100-150 . . . . . . . . . . . . . . . . . . . . . . . . . 200-300 . . . . . . . . . . . . . . . . . . . . . . . . . 300-450 . . . . . . . . . . . . . . . . . . . . . . . . . 420-600 . . . . . . . . . . . . . . . . . . . . . . . . 50-70 lb-ft . . . . . . . . . . . . . . . . . . . . . . . . 65-85 lb-ft . . . . . . . . . . . . . . . . . . . . . . . . 65-85 lb-ft (ALUMINUM OR STEEL UNIONS ONLY) . . . . . 60-75 lb-ft (ALUMINUM OR STEEL UNF PLAIN LOCKNUTS ONLY) . . . . 70-90-ft . . . . . . . . . . . . . . . . . . . . . . . . . . . 75-100 . . . . . . . . . . . . . . . . . . . . . . . . . 150-200 . . . . . . . . . . . . . . . . . . . . . . . . . 550-650 . . . . . . . . . . . . . . . . . . . . . . . . . 150-200 . . . . . . . . . . . . . . . . . . . . . . . . 60-75 lb-ft
PIPE PLUGS . . . . . . . . . . . . . TIGHTEN ENOUGH TO SEAL PLUGS USING COPPER OR ALUMINUM ASBESTOS GASKETS . . . . . . . . . . . . . . . . . . . . TIGHTEN AS REQUIRED, LOOSEN, RETIGHTEN ALUMINUM AND STEEL UNF BOLTS: 7/16-20 1/2-20 9/16-18 3/4-16 1 5/16-12 ALUMINUM CAPS: 7/16-20 7/16-20 9/16-18 9/16 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-65 11/16 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-65 11/16 . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-120 9/16 3/4 13/16 1 1 5/8 ......................... ......................... ......................... ......................... ......................... 150-200 175-225 200-250 200-250 200-250
UNF LOCKNUTS (NOTCHED HYDRAULIC): 7/16-20 9/16-18 1 1/16-12 3/4-16 1-7/8-12 11/16 7/8 1 3/8 1 2-1/8
ALUMINUM BUSHINGS:
* ALL TORQUES ARE POUND-INCHES UNLESS OTHERWISE SPECIFIED.
Figure 2.
Table of Standard Torque Values, Piping Assemblies
THREAD SIZE THREADS PER INCH MINIMUM INBUILT TORQUE*
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Page 7 MAXIMUM INBUILT TORQUE*
NOTE
1. 2. BEFORE USE OR REUSE, SELF-LOCKING DEVICES SHALL BE CHECKED TO VERIFY THAT THE SELF-LOCKING QUALITY IS SERVICEABLE. NUT LOCKING TORQUE IS THE TORQUE REQUIRED TO START THE NUT TURNING WHEN THE NUT IS ENGAGED WITH THE FULL CHAMFER OF THE BOLT OR STUD EXTENDING BEYOND THE LOCKING DEVICE OF THE NUT, AND THERE IS NO AXIAL LOAD ON THE NUT NUT. UNDER NO CIRCUMSTANCES SHALL THE LOCKING TORQUE OF THE DEVICE BE ALTERED BY CRIMPING OR BY TAPPING.
3.
No. 4 No. 4 No. 6 No. 6 No. 8 No. 8 No. 10 No. 10 1/4 1/4 5/16 5/16 3/8 3/8 7/16 7/16 1/2 1/2 9/16 9/16 5/8 5/8 3/4 3/4 7/8 7/8 1 1 1 1/8 1 1/4
40 48 32 40 32 36 24 32 20 28 18 24 16 24 14 20 13 20 12 18 11 18 10 16 9 14 8 12 12 12
0.5 0.5 1.0 1.0 1.5 1.5 2.0 2.0 4.5 3.5 7.5 6.5 12.0 9.5 16.5 14.0 24.0 18.0 30.0 24.0 40.0 32.0 60.0 50.0 82.0 70.0 110.0 90.0 117.0 143.0
5 5 10 10 15 15 18** 18** 30 30 60 60 80 80 100 100 150 150 200 200 300 300 400 400 50 lb-ft 50 lb-ft 67 lb-ft 67 lb-ft 75 lb-ft 83 lb-ft
* ALL TORQUES ARE POUND-INCHES UNLESS OTHERWISE SPECIFIED. POUND INCHES ** 13 POUND-INCHES FOR THREADED INSERT.
Figure 3.
Table of Standard Torque Values, Inbuilt Torque for Self-Locking Devices
THREAD SIZE WRENCH SIZE (INCHES) MATING PARTS OF STEEL TORQUE*
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Page 8
ONE OR BOTH MATING PARTS OF NON-STEEL TORQUE*
ELECTRICAL COUPLING NUTS 1/2-28 5/8 HEX . . . . . . . . . . . . . . . . . . . . . . . . . 5/8-24 3/4 HEX . . . . . . . . . . . . . . . . . . . . . . . . . 3/4-20 7/8 HEX . . . . . . . . . . . . . . . . . . . . . . . . . 7/8-20 1 HEX . . . . . . . . . . . . . . . . . . . . . . . . . 1-20 1 1/8 HEX . . . . . . . . . . . . . . . . . . . . . . . . . 1-20 SPANNER . . . . . . . . . . . . . . . . . . . . . . . . . 1 1/8-18 SPANNER . . . . . . . . . . . . . . . . . . . . . . . . . 1 1/4-18 SPANNER . . . . . . . . . . . . . . . . . . . . . . . . . 1 3/8-18 SPANNER . . . . . . . . . . . . . . . . . . . . . . . . . 1 1/2-18 SPANNER . . . . . . . . . . . . . . . . . . . . . . . . . 1 5/8-18 SPANNER . . . . . . . . . . . . . . . . . . . . . . . . . 1 3/4-18 SPANNER . . . . . . . . . . . . . . . . . . . . . . . . . 1/2-28 THRU 1 1/2-18 KNURLED . . . . . . . . . . . . . . . . 50-70 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-40 70-90 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-50 100-120 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-70 120-140 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-90 140-160 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100-125 140-160 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100-125 195-220 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100-125 245-270 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100-125 285-310 305-330 305-330 355-380 TIGHTEN BEYOND FINGER TIGHT (20_ MAX) UNTIL CONNECTING PARTS ARE IN SOLID CONTACT WITHOUT DAMAGE, THEN LOCKWIRE.
* ALL TORQUES ARE POUND-INCHES UNLESS OTHERWISE SPECIFIED.
Figure 4.
Table of Standard Torque Values, Electrical Coupling Nuts 32. INTERNAL WRENCHING FASTENER INSTALLATION. All installations shall be accomplished using the proper bit configuration. Do not use the following bits interchangeably within their groups: Phillips, Frearson, and Torq-Set; Socket (Hex) and Torx; Slotted and Hi-Torque. 33. Internal wrenching fasteners shall be torqued to values provided in NAVAIR 01-1A-8. Any additional clockwise movement after the fastener has been properly seated can increase the torque required for removal beyond normal requirements, which may be beyond the material capability of the fastener and result in cam-out. 34. Fasteners may be installed using screwdrivers, ratchets or speed wrenches as long as bits of the proper configuration are used. In all cases, sufficient end load shall be applied, care shall be taken to avoid wobble and the driver shall be kept in-line with the fastener centerline to prevent cam-out of the fastener recess and damage to the driver. When using speed wrenches, care shall be taken so that the bit does not become disengaged from the recess, thereby damaging the recesses and scratching or marring the surrounding structure.
30. INTERNAL WRENCHING FASTENER REMOVAL. Foreign material, including paint, shall be cleared from the recess prior to attempted fastener removal. In general this may be accomplished with the aid of a scribe or awl. When this technique is employed, care shall to exercised to ensure that the tool does not slip, thereby damaging the recess or scratching or gouging adjacent surfaces. Once foreign material is removed from the recess areas, fasteners can be removed by the simultaneous application of end load and torque. Care shall be exercised to ensure that the end load is great enough to avoid driver bit cam-out and that the driver is in-line with the fastener. Torque should be applied in a smooth, uniform manner. Do not snap load. As in the case of proper fastener installation, screwdrivers, ratchets, and speed wrenches (with proper bits) may be used for fastener removal. However, extreme caution shall be exercised to avoid tool wobble and bit cam-out. 31. Occasionally it is impossible to remove a fastener using normal practices. Generally this problem occurs when it is impossible to apply adequate end load and/or torque or when the fastener recess has been damaged due to bit cam-out. When these conditions occur, fastener removal tools or fastener extractors may be used.
002 00
Page 9
Figure 5.
Use of Torque Wrench Adapter
002005
35. AIRCRAFT HOSE AND TUBING.
002 00
Page 10 25AG2-3.05-3.6-.031, may be used to seal leaking V-band coupling joints in the bleed air system. Ensure duct flanges are in good condition before using gaskets. Use one gasket maximum per joint. 40. All V-band couplings in aircraft bleed air systems should be LS10042-300 couplings (Aeroquip MVT67651-300 or NUCO 435AE-300). Verify correct couplings by magnetic or visual inspection. Couplings shall have T-bolts that are nonmagnetic and marked by two grooves located on end of bolt. MS20995C32 Lockwire shall be installed on all bleed air system V-band couplings on the QECA and on the engine nacelle bleed air shutoff valve. Lockwire may be installed on remaining V-band couplings. 41. ELECTRICAL CONNECTORS.
36. Where information and direction are required relative to aircraft hose and tube fabrication, installation, testing, repair, inspection and storage, refer to NAVAIR 01-1A-20. Refer to Figure 2 for torque values. 37. TEFLON HOSES. Teflon hoses are relatively stiff at room temperature and are easily buckled and permanently damaged. Teflon should never be bent cold to an extent greater than possible with a similar size aluminum tube. Curved hoses are hot formed and clamped to a form block until room temperature is regained. After cooling, hose clamps and wires are used to hold the hose in the formed shape. Teflon hoses have a memory and tend to return to the straight condition when not wired in place. 38. No problem exists when the hoses are on the engine as they are supported in the right shape and the hot engine oil acts as a stress relief each time the engine is operated. When Teflon hoses are removed from the engine, they should be wired to retain their form until time of reinstallation. This provision is important where hoses are to be stored for a period of 24 hours or more. The only exceptions are the 1/4-inch hoses which are sufficiently flexible for normal handling. 39. V-BAND COUPLINGS.
NOTE
Refer to NAVAIR 01-75PAA-2-15.1, WP 048 00, for description of MS3459 electrical connector. 42. When installing/mating electrical connectors, inspect two halves for bent pins, deformed receptacles, corrosion, debris, moisture and any other deficiencies before assembly. Replace packings as required and lubricate with Dow Corning 33 bearing grease. Refer to NAVAIR 01-75PAA-2-15 series manuals for typical connector assembly. Torque conventional connector assemblies to the torque values specified in Figure 4. Secure with lockwire. (QA) 43. On aircraft BUNO 158918 and subsequent, the MS3459 self-locking connector is used in powerplant area (NAVAIR 01-75PAA-2-15.1, WP 048 00).
V-band couplings shall have T-bolts that are nonmagnetic and marked by two grooves located on end of bolt.
NOTE
Garlock gaskets, ALA STD 25AG2-2.12-2.60-.031 and ALA STD
Change 3 - 1 April 2001
003 00
Page 1
ORGANIZATIONAL MAINTENANCE DESCRIPTION AND PRINCIPLES OF OPERATIONS AIRCRAFT FUEL SYSTEM
Reference Material General Information and Servicing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . NAVAIR 01-75PAA-2-1 Fueling System Servicing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 011 00 Alphabetical Index Subject Aircraft Fuel System Component Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Aft Fuel Transfer Pump Conduit Overboard Drain, Aircraft BUNOs 150526 and Subsequent and Aircraft Incorporating AFC 53 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Boost Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Crossfeed Thermal Relief Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Dual Check Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Dump Pump, Aircraft BUNOs 153442 and Subsequent and Aircraft Incorporating AFC 188 . . . . . Dump Valve, Aircraft BUNOs 153442 and Subsequent and Aircraft Incorporating AFC 188 . . . . . Emergency Shutoff Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Float Vent Valve, P-3C Aircraft BUNOs 161129 and Subsequent and P-3A, P-3B and P-3C Aircraft Incorporating AFC 392 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fuel Tank Drain Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fuel Tank Shutoff and Crossfeed Shutoff Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fuel Tank Vent Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fuel Tank Vents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fueling and Transfer Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Interconnect Check Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . No. 5 Fuel Tank Pressure Gauge, P-3C Aircraft BUNOs 161129 and Subsequent and P-3A, P-3B and P-3C Aircraft Incorporating AFC 392 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Pilot Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Pressure Control Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Pressure Fueling Adapter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Pressure Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Recirculation Line Relief Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Sight Gauge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Transfer Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Aircraft Fuel System Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Aircraft Fueling System Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Aircraft-to-Engine Fuel Supply Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Aircraft-to-Engine Fuel Supply System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Crossfeed Manifold Pressure Indicator and Transmitter System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fuel Dumping System, Aircraft BUNOs 153442 and Subsequent and Aircraft Incorporating AFC 188 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fuel Quantity Indicating System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Page No. 28 31 46 48 48 47 47 48 45 48 47 45 31 43 48 46 43 46 43 47 46 49 46 2 4 19 8 19 8 19
Change 3 - 1 April 2001 Alphabetical Index (Continued) Subject
003 00
Page 2
Page No. 27 21 4 27 49 49 51 51 51 49
Fuel Quantity Indicators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fuel Quantity Tank Units (Transmitter Probes) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fueling-Defueling and Fuel Transfer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Indicator Test Switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fuel Tanks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Center Section Fuel Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Explosion Suppressant Foam Baffle System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fuel (Bladder) Cell Drain Mast . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fuselage Fuel Cell . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Wing Fuel Tanks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Record of Applicable Technical Directives
Type/No. AFC 188 AFC 578
Date 2 Mar 70
Title and ECP No. AIRFRAME, Increased Gross Weight and Fuel Dump Capability (ECP 494) SUSTAINED READINESS PROGRAM (SRP)
Date Inc. 15 Dec 70 15 AUG 98
Remarks
1.
AIRCRAFT FUEL SYSTEM DESCRIPTION.
2. The aircraft fuel system consists of five fuel tanks: a pressure fueling-defueling system (which includes a fuel transfer system), the engine supply system (which includes a crossfeed system), a vent system, a pump low pressure warning system, a crossfeed manifold pressure indicating system and a fuel quantity indicating system.
an auxiliary fuselage fuel tank. The auxiliary fuselage fuel tank consists of two separate interconnected fuel tanks, one of which is the integral wing center section fuel tank and the other a bladder cell fuel tank in the fuselage. Fuel is transferred from the auxiliary fuel tank to the engine feed fuel tanks providing additional fuel for engine feed. 4. The wing fuel tanks are to right (facing forward) and No. 2, No. 3 and No. 4 fuel fuel tank system is identified numbered from left identified as No. 1, tanks. The auxiliary as No. 5 fuel tank.
NOTE
For aircraft BUNOs 153442 and subsequent and aircraft incorporating AFC 188, a fuel dump system is provided. On P-3C aircraft BUNOs 161129 and subsequent and P-3A, P-3B and P-3C aircraft incorporating AFC 392, a float-operated pressure relief valve (float vent valve) and a larger vent line are incorporated for No. 1 and No. 4 fuel tanks. A fuel tank pressure-monitoring and overpressurization system is incorporated for No. 5 fuel tank. 3. The system contains four integral wing fuel tanks, each feeding fuel to a separate engine and
5. All main fuel system pumps, valves and most lines are mounted inside the fuel tanks to provide minimum fuel loss due to leakage. Refueling and shutoff valves are of the plug-in type and wing fuel tank pumps are serviced through doors in the top of the wing. Complete aircraft defueling is not necessary to service or maintain wing fuel tank fuel system primary components. 6. The fuel system is controlled from a FUEL MANAGEMENT panel (Figure 1). This panel is located in the flight station center console and has quantity gauges and switches to control all valves and pumps for each fuel transfer and crossfeed system.
Change 2 - 1 July 1998
003 00
Page 3
Figure 1.
Fuel Management Panel (AIRCRAFT NOT INCORPORATING AFC 578).
003001
003 00
Page 4
NOTE
The auxiliary power unit fuel system is controlled from the AUXILIARY POWER UNIT panel in the flight station on the center overhead panel. 7. FUELING-DEFUELING AND FUEL TRANSFER. Refer to NAVAIR 01-75PAA-2-1, WP 011 00, for fueling-defueling procedure. Normally, aircraft fueling is accomplished by center point pressure fueling (Figure 2). If pressure fueling equipment is not available, the wing fuel tanks can be fueled through overwing fillerwells At a pressure of 45 psi, the pressure fueling system is designed to fill all fuel tanks at a rate of 600 gallons per minute (gpm) at the two pressure fueling nozzle adapters. These adapters are located adjacent to each other just forward of the flaps in the aft inboard section of the right wing. 8. When overwing fueling, the time required to fuel is determined by the setting of the fueling truck. One truck pumping at 70 gpm through a 1 1/2 inch hose and nozzle requires 2 hours to complete fueling. 9 A fueling control panel (Figure 3) is located between the nozzle adapters; the operator faces aft to read it. The panel contains quantity gauges for the five fuel tanks, fueling valve control and test switches, power switches and indicator lights. When the fuel tanks are full, fueling terminates automatically; however, the operator may fill fuel tanks to any quantity by manually operating the switches on the control panel. A hinged access door covers the control panel and nozzle adapters when not in use. 10. On P-3C aircraft BUNOs 161129 and subsequent and P-3A, P-3B and P-3C aircraft incorporating AFC 392, a fuel tank pressure-monitoring and overpressurization system is incorporated for No. 5 fuel tank. A pressure gauge is incorporated on a small lighting panel forward of the fueling control panel and is connected to No. 5 fuel tank. 11. Fuel flows from the nozzle adapters through a diverter which directs the fuel to three manifolds mounted within the fuel tanks. One manifold supplies engine feed fuel tanks in the right wing, a second manifold supplies engine feed fuel tanks in the left wing and a third manifold supplies the center section fuel tank and fuselage cell. A fueling valve installed in each fuel tank controls fuel flow
into that fuel tank. A pilot valve controls the fueling valve. 12. The fueling valves in the auxiliary fuel tank are used for fueling and defueling only and are controlled from the fueling control panel. Wing fuel tank fueling valves are controlled from the fueling control panel when used for fueling. When used for fuel transfer, the wing fuel tank fueling valves are controlled from the flight station FUEL MANAGEMENT panel. 13. Two dual-element pumps in the fuselage cell transfer fuel from the auxiliary fuel tank to all four engine feed fuel tanks. The engine feed fuel tanks are maintained full until the auxiliary fuel tank is depleted. 14. AIRCRAFT FUELING SYSTEM CIRCUIT. To fuel the aircraft, the SYSTEM POWER switch on the fueling control panel is set to ON. This energizes two master refueling relays in the main load center and arms the high level fuel tank shut-off circuit (Figure 4). The master refueling relays allow the wing and fuselage fueling valves to be controlled exclusively from the fueling control panel by disabling the control switches on the FUEL MANAGEMENT panel and causing the reset indicator lights to come on, indicating that these control switches are disabled. 15. The VALVE CLOSED INDICATION indicators are powered through the fueling control panel access door switch. Therefore, all of these lights must come on when the door is opened. If all the lights do not come on, the INDICATOR LIGHTS TEST switch may be pressed to bypass normal gr ou nd th r oug h th e v alv e f or t he p ur pos e of checking the light and associated wiring. If the INDICATOR LIGHTS TEST switch causes the indicators to come on, the corresponding valve may not be fully closed. The indicator should function properly when fueling pressure is applied at the valve. 16. The high level fuel tank shutoff test circuit is used to determine whether the primary and secondary valves of the fueling valves close when high fuel level in the fuel tank is reached. This is checked at the fueling control panel by setting and holding the FUEL SHUT-OFF TEST switch to PRIMARY. With fuel pressure applied, the FUELING VALVE CONTROL SWITCHES are set to OPEN. The VALVE CLOSED INDICATION indicators must go off and come on again in 5 to 15 seconds. If the
003 00
Page 4A/(4B Blank)
003001a
Figure 1A.
Fuel Management Panel (AIRCRAFT INCORPORATING AFC 578).
003 00
Page 5/(6 Blank)
003002
Figure 2.
Aircraft Fueling-Defueling and Fuel Transfer System Schematic
003 00
Page 7
Figure 3.
Fueling Control Panel
003003
003 00
Page 8
respective VALVE CLOSED INDICATION indicator is on, it indicates proper operation of the primary valve in both the pilot and fueling valve. After checking all primary valves, the FUEL SHUT-OFF TEST switch is set to SECONDARY and held while the secondary valves of the pilot and fueling valves are checked in the same way the primary valves were checked. After completing all checks the FUEL SHUT-OFF TEST switch is set to OFF. 17. After checking pilot and fueling valve operation, the FUELING VALVE CONTROL SWITCHES are set to OPEN. This energizes a solenoid valve in each fueling valve which permits the fueling valves to open and admit fuel to the fuel tanks. The solenoid valves receive power from the main dc bus at the main load center through circuit breakers and contacts of the master relays and closed contacts of the FUELING VALVE CONTROL SWITCHES. When the fuel tanks are full, as indicated by the fuel tank FUEL QUANTITY gauges at the fueling control panel, the fueling valves automatically close. The FUELING VALVE CONTROL SWITCHES are then set to CLOSED, which deenergizes the fueling valve solenoid valves. The SYSTEM POWER switch is set to OFF which deenergizes the master relays to switch fuel tank fueling valve control to the FUEL MANAGEMENT panel at the flight station center console. This disarms the high level fuel tank shutoff circuit. 18. Fuel transfer from the auxiliary fuel tank to the engine feed fuel tanks is controlled from the FUEL MANAGEMENT panel. The FUEL TRANSFER RESET advisory indicator on the panel must be off or fuel transfer cannot be accomplished. Actuation of the FUEL TRANSFER RESET switch removes the ground from the fueling control panel mounted SYSTEM POWER switch which deenergizes the master relays and transfers fueling valve control to the FUEL MANAGEMENT panel control switches. 19. To accomplish fuel transfer, the two TRANSFER PUMP switches on the FUEL MANAGEMENT panel are set to TRANSFER PUMP. This routes power from the extension main dc bus at the forward load center through circuit breakers to the pump control relays resulting in completion of the ac power circuits to the transfer pumps. The forward transfer pump receives power through a circuit breaker on the main ac bus A at the main load center. The aft transfer pump receives power from the main ac bus B at the main load center.
20. Setting the four TRANSFER VALVE switches on the FUEL MANAGEMENT panel to OPEN routes power from the main dc bus to the wing fuel tank fueling valve solenoids permitting fuel transfer to the wing fuel tanks. 21. FUEL DUMPING SYSTEM, AIRCRAFT BUNOs 153442 AND SUBSEQUENT AND AIRCRAFT INCORPORATING AFC 188. The system dumps fuel from No. 5 fuel tank only, to reduce the landing weight to within allowable limits with a corresponding reduced vertical sink rate during landing (Figures 5 and 6). 22. The system incorporates a fixed dump chute and flame arrester which extends over the left wing trailing edge. Fuel is dumped by use of an electrically driven jettison pump installed in No. 5 fuel tank adjacent to the fuel tank access panel. 23. The transfer pumps in No. 5 fuel tank bladder cell are also simultaneously activated to augment jettison flow. A check valve is installed to prevent backflow to the jettison pump during normal fuel transfer. 24. A single switch is provided at the flight station left outboard overhead panel (fuel dump panel) which, when activated, simultaneously starts the jettison pump and the fuel transfer pumps and opens a dump valve on the rear beam of the left wing allowing fuel to flow overboard. The time required to evacuate a full No. 5 fuel tank is approximately 17 minutes. 25. AIRCRAFT-TO-ENGINE FUEL SUPPLY SYSTEM. Each of the four wing fuel tanks supplies fuel to its respective engine. If necessary, fuel may be supplied to alternate engines through the crossfeed system. 26. A surge box is located in each wing fuel tank with a flapper type check valve in the lower inboard corner of the box forward wall (Figure 7). The surge box is in the aft inboard corner of the fuel tank. The flapper valve traps fuel in the surge box, ensuring boost pump inlet is always submerged in fuel. 27. A dual element pump is mounted in each surge box. The scavenge element of the pump supplies fuel to the surge box from the fuel tank low point. This ensures boost pump inlet submergence during landing and maneuvering with very low fuel levels. The boost pump pressurizes the engine feedline, delivering fuel at the required flow to the engine-driven fuel pump. The
003 00
Page 9/(10 Blank)
00300401
Figure 4.
Aircraft Fuel System Circuit Schematic (Sheet 1 of 2)
003 00
Page 11/(12 Blank)
00300402
Figure 4.
Aircraft Fuel System Circuit Schematic (Sheet 2)
003 00
Page 13
003005
Figure 5.
Fuel Dumping System Circuit Schematic, Aircraft BUNOs 153442 and Subsequent and Aircraft Incorporating AFC 188
003 00
Page 14
Figure 6.
Fuel Dumping System, Aircraft BUNOs 153442 and Subsequent and Aircraft Incorporating AFC 188
003006
003 00
Page 15/(16 Blank)
00300701
Figure 7.
Aircraft to Engine Fuel Supply, Crossfeed and Fuel Vent System Schematic (Sheet 1 of 2)
003 00
Page 17/(18 Blank)
00300702
Figure 7.
Aircraft to Engine Fuel Supply, Crossfeed and Fuel Vent System Schematic (Sheet 2)
engine-driven fuel pump has the capacity to provide required fuel flow to the engine if the fuel tank boost pump is inoperative. 28. Fuel enters the engine feedline from either the boost pump, or a pump bypass, if the pump is off. Fuel passes through an eight-mesh screen of approximately 40 square inch area before entering the engine feedline. A spring-loaded bypass valve on the screen allows fuel flow if the screen is clogged. 29. At the junction of the boost pump discharge port and the pump bypass, fuel passes through a dual check valve. The dual check valve prevents fuel flow from entering the fuel tank during crossfeeding if the fuel tank shutoff valve is open. 30. From the dual check valve, the engine feedline, mounted inside the fuel tank, is plumbed to an electrically operated fuel tank shutoff valve and a cable operated emergency shutoff valve at the wing front beam. The engine fuel feedline is mounted in the nacelle forward of the front beam and feeds through a combination strainer and heater which is upstream from the engine-driven boost pump. 31. The crossfeed system permits any engine feed fuel tank to supply fuel to any engine. However, fuel cannot be transferred from fuel tank to fuel tank through this system. The crossfeed manifold is mounted within the fuel tanks just aft of the wing front beam. Five valves control the system, one in each feed fuel tank adjacent to the fuel tank shutoff valve in the engine feedline and one in No. 2 fuel tank in the crossfeed manifold to prevent crossfeed from one side of the aircraft to the other during multiple crossfeeding. 32. AIRCRAFT-TO-ENGINE FUEL SUPPLY CIRCUIT. Fuel boost pumps receive power through separate circuit breakers at the main load center main ac buses (Figure 4). Main ac bus A supplies boost pumps No. 1 and No. 3. Main ac bus B supplies boost pumps No. 2 and No. 4. Power is delivered to each pump through individual pump control relays at the main load center. 33. Setting the BOOST PUMP switches on the FUEL MANAGEMENT panel on the flight station center console to BOOST PUMP directs power from circuit breakers on the extension main dc bus at the forward load center to the pump control relay coils, closing the ac power circuits to the pumps.
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Page 19 34. The fuel tank shutoff valves must be open to allow fuel flow to the engines. The MAIN FUEL TANK VALVE switches on the FUEL MANAGEMENT panel are set to OPEN directing power from circuit breakers on the monitorable essential ac bus at the forward load center to the fuel tank shutoff valves, opening the valves for fuel flow to the engines. 35. Crossfeed of fuel from an engine feed fuel tank to an engine other than its respective engine is accomplished by setting the appropriate CROSSFEED valve switches on the FUEL MANAGEMENT panel to OPEN. Power is then supplied from a circuit breaker on the monitorable essential ac bus at the forward load center to the crossfeed valve actuator, opening the valve for crossfeed of fuel. 36. CROSSFEED MANIFOLD PRESSURE INDICATOR AND TRANSMITTER SYSTEM. The fuel crossfeed manifold pressure indicating system consists of an indicator on the FUEL MANAGEMENT panel and a transmitter located on the left wing front beam at approximately WS 22 (Figure 8). The transmitter is a synchrogenerator that is mechanically connected to a pressure sensing device. The pressure sensing device changes the position of the synchrogenerator rotor with a change in pressure. The indicator is a synchromotor with its rotor connected to a pointer. The pointer indicates the pressure in the fuel crossfeed system and can be used to read boost pump pressure in the fuel crossfeed system and pump pressure applied to the crossfeed system (to display pump performance). The transmitter and indicator have a range of 0 to 50 psi. The synchros are energized from the 26 vac bus transformer No. 2 at the forward load center aft circuit breaker panel. 37. FUEL QUANTITY INDICATING SYSTEM. A capacitor fuel quantity indicating system is a fuel quantity measuring system based on the principle that the capacitance of any capacitor in an electrical circuit is determined by the dielectric constant of the material between its plates. In this system, fuel tank units (transmitter probes) are immersed in fuel and function as variable capacitors. Their capacitance varies with the proportion of fuel and air between the plates of the fuel tank units. The master indicator is a continuously rebalanced bridge circuit in which the capacitance of the fuel tank units is compared to a reference capacitor. A signal, proportional to the difference between them, is amplified to operate a motor which restores the system
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Figure 8.
Crossfeed Manifold Pressure Indicator Circuit
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to balance. The degree of correction is an indication of the capacitance of the fuel tank units and thus an indication of the quantity of fuel in the fuel tank. 38. AIRCRAFT NOT INCORPORATING AFC 578: The aircraft fuel system consists of two fuel tanks in each wing and two interconnected fuel tanks in the fuselage (Figures 9 and 10). The outboard wing fuel tanks (No. 1 and No. 4 fuel tanks) contain five fuel tank units each. The inboard wing fuel tanks (No. 2 and No. 3 fuel tanks) and the inter-connected fuselage fuel tanks (No. 5 fuel tank) contain three fuel tank units each. All wing fuel tank units are externally flush-mounted with interconnecting wire inside the fuel tanks. The fuselage fuel tank units are externally bottom-mounted with the wiring external to the fuel tanks.
AIRCRAFT INCORPORATING AFC 578: Wing tank probes are identified inboard (surge box probe being No. 1) to outboard. 38A. AIRCRAFT INCORPORATING AFC 578. The aircraft fuel system consists of two fuel tanks in each wing and two interconnected fuel tanks in the fuselage (figures 9 and 10). The outboard wing fuel tanks (No. 1 and No. 4 fuel tanks) contain six fuel probes each. One of the fuel probes is located in the surge box of each main tank. The inboard wing fuel tanks (No. 2 and No. 3 fuel tanks) contain four fuel probes each, with one of the fuel probes located in the surge box of each main tank. The inter-connected fuselage fuel tanks (No. 5 fuel tank) contains three fuel probes. All wing fuel probes except surge box probes are externally flush-mounted with interconnected wire inside the fuel tanks. The fuselage fuel probes are externally bottom-mounted with the wiring external to the fuel tanks. 38B. AIRCRAFT INCORPORATING AFC 578. Fuel quantity is calculated by the Digital Fuel Quantity System (DFQS). A dual channel attitude sensor unit is
AIRCRAFT NOT INCORPORATING AFC 578: Wing tank probes are identified outboard to inboard, unit No. 1 being closest to the wing tip.
Change 2 - 1 July 1998 used to improve the fuel gauging accuracy over the required attitude range. The unit provides aircraft pitch and roll to the four flight station indicators for fuel tanks No. 1, No. 2, No. 3, and No. 4. Indicators use this information to correct attitude errors that are inherent in the system. Tanks 1 and 4 are subject to greater wing flex during flight which affects the fuel quantity reading. The DFQS Scissor Relay (Figure 10) provides flight station indicators No. 1 and No. 4 with ground/flight information that is used in conjunction with the dual channel attitude sensor to correct for attitude errors in the fuel quantity reading. The DFQS Scissor Circuit test switch on the Forward Circuit Breaker Panel provides a maintenance function to test the air/ground circuit. 39. AIRCRAFT NOT INCORPORATING AFC 578. An integral compensator unit is located at the lowest portion of the one fuel tank unit which senses the lowest fuel level in each fuel tank. The compensator minimizes the error due to variations in the dielectric constant of the fuel. 39A. AIRCRAFT INCORPORATING AFC 578. The DFQS provides fuel quantity accuracy based on MIL-G-26988C with JP-5 as primary fuel. The system is compatible with foamed and non-foamed fuel tanks.
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Page 21 40. AIRCRAFT NOT INCORPORATING AFC 578: FUEL QUANTITY TANK UNITS (TRANSMITTER PROBES). Basically, each fuel tank unit consists of two fiberglass tubes separated by a relatively large air gap (Figure 11). Deposited on the tubes are conductive coatings which act as the plates of a capacitor. These coatings are patterned or profiled in such a way as to compensate for the effects of an irregularly shaped fuel cell. To protect the delicate coatings, the tubes are covered with an epoxy varnish and bonded to a metal flange which serves to mount the unit in the fuel cell. 41. The capacitance of any capacitor is determined by three variables: area of the plates, distance between the plates and dielectric value of the insulating material between the plates. 42. The fuel tank units are fixed both in plate area and in the distance between the plates. Therefore, the capacitance of the fuel tank unit changes only with a change in the dielectric value of the material between the plates. With the fuel tank unit immersed in fuel in a fuel tank, the dielectric material is partially fuel and partially air; the proportions being determined by the level of fuel in the fuel tank. Thus, the capacitance of the fuel tank unit varies directly with fuel quantity.
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Figure 9. Fuel Quantity System Functional Block Diagram (AIRCRAFT NOT INCORPORATING AFC 578)
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Page 23
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Figure 9A.
Fuel Quantity System Functional Block Diagram (AIRCRAFT INCORPORATING AFC 578)
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Figure 10.
Fuel Quantity Indicating System Electrical Block Diagram (AIRCRAFT NOT INCORPORATING AFC 578)
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Figure 10A. Fuel Quantity Indicating System Electrical Block Diagram (AIRCRAFT INCORPORATING AFC 578)
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Page 26
Figure 11.
Fuel Quantity Probes and Indicators
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Change 2 - 1 July 1998 43. All of the fuel tank units are flange mounted in the fuel tanks. Fuselage fuel tank units are bottom-mounted and accessible through a hinged access door in the fuselage underside. Wing fuel tank units are top mounted and accessible from the top of the wings. 44. Compensated fuel tank units contain an additional auxiliary compensator at their lowest point in the fuel tank. These units are constantly immersed in fuel and thus their capacitance varies not with fuel level but only with the different dielectric constants of various fuels. 44A. AIRCRAFT INCORPORATING AFC 578: FUEL QUANTITY TANK UNITS (TRANSMITTER PROBES). Each fuel tank probe consists of two concentric metal tubes separated by a relatively large air gap (Figure 11). Deposited on the tubes are conductive coatings which act as the plates of a capacitor. The inside tube is patterned or profiled in such a way as to compensate for the effects of an irregularly shaped fuel cell. The tubes are bonded to a metal flange which serves to mount the unit in the fuel cell. 44B. The capacitance of any capacitor is determined by three variables; area of the plates, distance between the plates, and dielectric value of the insulating material between the plates. 44C. The fuel tank probes are fixed both in plate area and in the distance between the plates. Therefore, the capacitance of the fuel tank probe changes only with a change in the dielectric value of the material between the plates. With the fuel tank probe immersed in fuel in a fuel tank, the dielectric material is partially fuel and partially air; the proportions being determined by the level of fuel in the fuel tank. Thus, the capacitance of the fuel tank probe varies directly with fuel quantity.
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Page 27 bottom-mounted and accessible through a hinged access door in the fuselage underside. Wing fuel tank probes are top mounted and accessible from the top of the wings.
45. AIRCRAFT NOT INCORPORATING AFC 578: FUEL QUANTITY INDICATORS. Two basic types of indicators are used in the fuel quantity indicating system (Figure 12). One type of indicator is used as either a master indicator at the flight station FUEL MANAGEMENT panel or as a repeater indicator on the fueling control panel. Master or repeater indicators for the wing fuel tanks are interchangeable with each other. However, the fuselage fuel tank master is interchangeable only with its repeater. The second type of indicator is the totalizer indicator. Only one totalizer indicator is required in the system. This totalizer is installed at the FUEL MANAGEMENT panel.
45A. AIRCRAFT INCORPORATING AFC 578: INDICATORS. Two types of digital indicators are used. There are six flight stations indicators with five used as individual tank fuel quantity indicators and one used as a Totalizer. Each flight station indicator can read fuel probe signals, calculate fuel quantity, display BIT function codes, and provide data channels to provide fuel quantity and BIT data to its repeater and to the flight station Totalizer. All flight station fuel quantity indicators are interchangeable with other fuel quantity indicators within the Fuel Management Panel. The second type of indicator is a repeater indicator used at the fueling panel. There are five fueling panel indicators. Each receives fuel quantity data and BIT data from its respective flight station indicator. The No. 5 tank repeater also receives total fuel quantity for user selectable display by use of the TANK 5/TOTAL FUEL switch on the fueling panel. Each repeater indicator is interchangeable with the other repeater indicators.
AIRCRAFT INCORPORATING AFC 578, Wing tank probes are identified inboard (surge box probe being No. 1) to outboard. 44D. The surge box fuel tank probes mount in brackets and are accessible through the Fuel Boost Pump Access panels (Tank 1, W110-L; Tank 2, W109-L; Tank 3, W109-R; Tank 4, W110-R). The remaining fuel tank probes are flange mounted in the fuel tanks. Fuselage fuel tank probes are
NOTE Each indicator is interchangeable within its respective panel, but is not interchangeable between panels.
46. AIRCRAFT NOT INCORPORATING AFC 578: INDICATOR TEST SWITCHES. A test switch is located
Change 2 - 1 July 1998 on the FUEL MANAGEMENT panel and on the fueling control panel at the right wing fillet. Any indicator that does not move downscale when a test switch is pressed may be defective. 46A AIRCRAFT INCORPORATING AFC 578: INDICATOR TEST SWITCHES. Pressing the FUEL GAGE TEST switch on the Fuel Management panel provides a display test, and fault code display. Pressing the TEST switch on the Fueling System panel provides a display test, and fault code display on the Fueling System panel indicators. Any detected failures are stored in non-volatile memory of the indicators for later retrieval by maintenance personnel. Refer to NAVAIR 01-75PAC-2-13.1.2 for detailed BIT information. 46B. AIRCRAFT INCORPORATING AFC 578: DUAL CHANNEL ATTITUDE SENSOR UNIT. The dual channel attitude sensor unit is used to provide improved fuel gauging accuracy over the required attitude range. It provides aircraft pitch and roll information to the flight station indicators which use this information to correct attitude errors that are inherent in the system. The Attitude Sensor contains two identical, electrically isolated pitch and roll sensors used individually by Main Tank indicators 1 thru 4. Attitude errors are corrected for tanks 1 through 4 but not for tank 5. The fuel quantity read from the tank fuel probes are corrected based upon the aircraft attitude region. Refer to NAVAIR 01-75PAC-2-13.1.2 for detailed dual channel attitude sensor unit information. 47. AIRCRAFT FUEL SYSTEM COMPONENT DESCRIPTION. 48. Aircraft fuel system components are listed in Table 1. The locations of these components are shown in Figures 13 and 14. Table 1. Aircraft Fuel System Components Number Per Aircraft 2 Table 1.
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Page 28 Aircraft Fuel System Components (Cont) Number Per Aircraft 4
Component Cap and Screen for Overwing Fueling Fillerwell Fuel Dump Flame Arrester
Location Top of wing just outboard of inboard nacelles and near wing tips Left wing trailing edge, outboard of WS 101 Flight station center console
FUEL MANAGEMENT Panel Fuel Tanks
Two integral in each wing (1, 2, 3 and 4), one integral wing center section in fuselage rubber bladder cell Right wing trailing edge to fuselage fillet Forward of fueling control panel FUEL MANAGEMENT panel
Fueling Control Panel
No. 5 Fuel Tank Pressure Gauge Crossfeed Manifold Pressure Indicator Fuel Quantity Indicator
10
Component Fueling Adapter with Cap for Centerpoint Fueling
Location Right Wing trailing edge to fuselage fillet Fuel Totalizer Indicator 1
Five each, in FUEL MANAGEMENT panel and fueling control panel FUEL MANAGEMENT panel
Change 2 - 1 July 1998 Table 1. Aircraft Fuel System Components (Cont) Number Per Aircraft 4 Table 1.
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Page 29 Aircraft Fuel System Components (Cont) Number Per Aircraft 5
Component Dual Element Boost Pump
Location One each in surge boxes of No. 1, No. 2, No. 3 and No. 4 fuel tanks No. 5 fuel tank, aft compartment In fuselage bladder cell Main load center
Component Crossfeed Valve Control Switch Fuel (Bladder) Cell Drain Mast
Location FUEL MANAGEMENT panel Lower fuselage centerline at FS 524 Flight station fuel dump panel One each on FUEL MANAGEMENT panel and fueling control panel Fueling control panel
Fuel Dump Pump Dual Element Transfer Pump Aft Fuel Transfer Pump Relay Boost Pump Control Relay Forward Fuel Transfer Pump Relay Fuel Dump Pump Relay Fuel Dump Valve Relay Fuel Quantity Test Relay Master Relay Transfer Pump Control Relay Boost Pump Control Switch
Fuel Dump Switch Fuel Quantity Test Switch
Main load center
Main load center
Fuel Tank High Level Test Switch Fueling Valve Control Switch
Fueling control panel Fueling control panel FUEL MANAGEMENT panel
Main load center
Master Switch
Main load center
Flight station center console Main load center Main load center
Normal Control for Fuel Tank Shutoff Valve Switch Refueling Panel Service Switch
2 2
On door frame of fueling control panel access door FUEL MANAGEMENT panel
FUEL MANAGEMENT panel On wing rear beam in wing flap well
Reset Switch
Boost Pump Pressure Warning Switch
Change 2 - 1 July 1998 Table 1. Aircraft Fuel System Components (Cont) Number Per Aircraft 2
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Page 30 Table 1. Aircraft Fuel System Components (Cont) Number Per Aircraft 5
Component Transfer Pump Pressure Warning Switch
Location In fuselage compartment between bladder cell and center section fuel tank FUEL MANAGEMENT panel FUEL MANAGEMENT panel In fuselage compartment between bladder cell and center section fuel tank Five in outboard, three in inboard, one in bladder cell and two in center section fuel tanks Six in outboard, four in inboard one in bladder cell and two in center section fuel tanks Lower shelf near the floor of Electronics Rack C1/C2 On bladder cell to center section fuel tank interconnect line in bladder cell
Component Crossfeed Shutoff Valve
Location Two in No. 2 fuel tank, one each in No. 1, No. 3 and No. 4 fuel tanks; all in wing front beam One each in No.1, No. 2, No. 3 and No. 4 fuel tanks and bladder cell and two in center section fuel tank One each in surge boxes of No. 1, No. 2, No. 3 and No. 4 fuel tanks In bladder cell on rear bulkhead
Transfer Pump Control Switch
Condensate and Fuel Drain Valve
Transfer Valve Control Switch
Crossfeed Pressure Transmitter
Dual Check Boost Pump Bypass Valve
Fuel Quantity 19 Transmitter (Aircraft not incorporating AFC 578)
Dual Check Transfer Pump Valve Emergency Fuel Tank Shutoff Valve
Fuel Quantity 23 Transmitter (Aircraft incorporating AFC 578)
One each in No.1, No.2, No.3 and No.4 fuel tanks in wing front beam One each in No. 1 and No. 4 fuel tanks Rear beam, outboard of WS 101 One each in bladder cell and center section in fuselage compartment
Float Vent Valve
Dual Channel Attitude 1 Sensor Unit (Aircraft incorporating AFC 578) Ball Check Valve 1
Fuel Dump Valve
Fueling-Defueling Valve
Change 2 - 1 July 1998 Table 1. Aircraft Fuel System Components (Cont) Number Per Aircraft 4 NOTE
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Component Fueling-Defueling Transfer Valve
Location One each in No.1, No.2, No.3 and No.4 fuel tanks in wing rear beam in flap well One each in No.1, No.2, No.3 and No.4 fuel tanks in wing front beam One in each fuel tank At transfer pump outlets in bladder cell Center section fuel tank
On P-3C aircraft BUNOs 161129 and subsequent and P-3A, P-3B and P-3C aircraft incorporating AFC 392, an additional float vent valve and a larger vent line are incorporated for No. 1 and No. 4 fuel tanks.
Main Fuel Tank Shutoff Valve
Pilot Valve
49. AFT FUEL TRANSFER PUMP CONDUIT OVERBOARD DRAIN, AIRCRAFT BUNOs 150526 AND SUBSEQUENT AND AIRCRAFT INCORPORATING AFC 53. A drain tube is installed at the FS 553 bulkhead which extends from the bladder cell aft fuel transfer pump conduit down through the fuselage lower skin at approximately FS 558. The drain is identified as the TRANSFER PUMP CONDUIT DRAIN by a decal on the outer skin. It permits fuel seepage into the conduit to drain overboard.
Pressure Control Valve
Center Section Fuel Tank Sight Gauge Recirculating Relief Valve
50. FUEL TANK VENTS. The outlets for all fuel tank vent lines terminate 28 to 38 inches from the edge of the wingtips on the lower wing surface just forward of the ailerons. The auxiliary fuel tank vent outlet is at the left wingtip. The vent outlets are the flush static type equipped with flame arrestors.
One each in No. 2 and No.3 fuel tanks in outboard ends of recirculation lines One each in No.1, No.2, No.3 and No.4 fuel tanks, bladder cell and center section fuel tanks In center section vent line in center section fuel tank
Vent Valve
51. The auxiliary fuel tank vent system has a flush non-icing ram scoop. The ram scoop is located in the wing center section lower trailing edge skin, left side just inboard of WS 65. This ram scoop is plumbed into the auxiliary fuel tank vent line in the center section fuel tank. A check valve is installed in the ram line at the junction to the vent line. This permits ram air to enter the vent system, but prevents the exhausting of vent fumes through the ram scoop.
Vent Check Valve
52. All fuel tanks are equipped with vent valves to minimize spillage and to prevent siphoning of fuel overboard during maneuvers. Each vent valve incorporates a pressure relief valve and a vacuum relief valve.
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Page 32 53. The vent line for the interconnect auxiliary fuel tanks is routed from vent domes on each fuel tank to a junction above the fuel tanks, through the upper surface of the center section fuel tank and then through the left wing fuel tanks to the tip outlet. The junction is located to avoid the possibility of its being covered with fuel when
NOTE
On P-3C aircraft BUNOs 161129 and subsequent and P-3A, P-3B and P-3C aircraft incorporating AFC 392, an additional float vent valve and a larger vent line are incorporated for No. 1 and No. 4 fuel tanks.
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Page 33/(34 Blank)
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Figure 12.
Fuel Quantity Indicating System Components.
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Page 35/(36 Blank)
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Figure 13.
Aircraft Fuel System Units Location, Aircraft BUNOs 148883 through 153441 (Sheet 1 of 2)
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Page 37/(38 Blank)
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Figure 13.
Aircraft Fuel System Units Location, Aircraft BUNOs 148883 through 153441 (Sheet 2)
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Page 39/(40 Blank)
Figure 14.
Aircraft Fuel System Units Location, Aircraft BUNOs 148883 through 153441 (Sheet 1 of 2)
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Page 41/(42 Blank)
Figure 14.
Aircraft Fuel System Units Location, Aircraft BUNOs 153442 and Subsequent (Sheet 2)
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Change 2 - 1 July 1998 topping off fuel tanks with the aircraft at 3 degrees ground slope. The vent valves provide additional protection in this respect at ground angles in excess of 3 degrees. The fuel tank vent domes also permit maximum fuel tank capacities with respect to total volume available. 54. Because of structural interference, a low point results in the auxiliary fuel tank vent line. This low point is drained with a 3/8 inch diameter open drain line overboard through a mast in the wing trailing edge panel. This location provides positive drainage under all flight conditions including maximum emergency descent angle. 55. The auxiliary fuel tank vent system is designed to limit the bladder cell pressure differential to 0.25 psi (in the direction tending to collapse the cell) for emergency descent condition. If the vent valve should fail in the closed position, an integral suction relief valve limits the cell negative pressure to 0.5 psi maximum. The bladder cell fuel tank and support system is designed to withstand 1.0 psi negative pressure without damage. Positive bladder cell pressures above the fuel resulting from the ram vent are approximately 3.0 psi at maximum flight speed conditions. 56. The airspace above the pressure fueling pilot valve in all fuel tanks is limited to the amount necessary to suitably install the pilot valve and vent valves. This results in an air space between the pilot valve shutoff level and the vent valve pressure relief. 57. The vent space concept provides for maximum efficiency of fuel tank volume-to-aircraft weight. A fuel topping off procedure, before flight, prevents fuel spillage through the vent outlets due to fuel expansion. 58. The vent spaces in No. 2 and No. 3 fuel tanks are connected to the vent space of the center section fuel tank by recirculation lines 1 1/2 inches in diameter and are equipped with poppet valves at the vent space ends in No. 2 and No. 3 fuel tanks. These valves function the same as the relief poppet valves used in the vent valves for these fuel tanks. The recirculation lines provide protection against wing structure damage in event of dual failure of the fuel transfer system by providing for overflow relief, returning the overflow fuel back to the center section fuel tank.
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Page 43 59. PRESSURE FUELING ADAPTER. Two pressure fueling valve adapter assemblies are located just forward of the flaps in the aft inboard section of the right wing at WS 52, FS 710. Each assembly consists of a nozzle receptacle and flow distribution fitting with a pressure sealing cap chained to the fitting. Each valve operates at a pressure of 45 psi and allows a flow rate of 300 gpm. 60. FUELING AND TRANSFER VALVE. At each fuel tank inlet, a fueling valve is installed to control fuel flow to that fuel tank (Figure 15). The engine feed fuel tanks have the fueling valves mounted in the left and right wing rear beam at WS 110 for inboard fuel tanks and WS 260 for outboard fuel tanks. The valves are accessible from the wing flap well. These valves also control fuel flow during transfer from the auxiliary fuel tank to the engine feed fuel tanks. The fueling valve in the fuselage cell is mounted in the FS 553 bulkhead and the center section fuel tank valve is mounted in the wing front beam. Both valves are accessible through a door in the fuselage lower skin just forward of the wing front beam. 61. The fueling valves contain two poppets or pistons in series, designated as primary and secondary which are controlled by a solenoid energized from the main dc bus at the main load center. The chambers behind the poppets are connected to the pilot valve which controls fueling valve shut-off by the pilot valve primary and secondary lines. Normal valve operating pressure is 5 to 45 psi with a maximum allowable surge pressure of 100 psi. The maximum allowable flow rate is 259 gpm. 62. Defueling the aircraft to service the valves is not necessary since the valve body plugs into the valve housing through the fuel tank wall. When the valve body is rotated for removal from the housing, an element is rotated over the port preventing fuel spillage. 63. PILOT VALVE. A pilot valve is installed at the high point of each fuel tank to control the fueling valve for that fuel tank. Pilot valves in the left and right outboard wing fuel tanks are located between WS 567 and WS 584 and in the inboard wing fuel tanks between WS 204 and WS 221. The pilot valve in the fuselage cell is located at approximately FS 484 to the right of the centerline. In the center section fuel tank, the pilot valve is located at approximately FS 621 to the right of the centerline and is removed through an access hole in the bottom of the
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Page 44
Figure 15.
Fueling and Transfer Valve and Pilot Valve Schematic
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Change 2 - 1 July 1998 fuselage directly below the valve. The valve is mounted on a bayonet fitting. The fuselage cell valve is accessible through an access door in the bomb bay aft bulkhead and the wing fuel tank valves are accessible through small cover plates directly over the units. 64. The pilot valve is a dual float-operated valve with a primary float and a secondary float. The primary and secondary float valves are connected to the primary and secondary pilot ports of the fueling valve by fuel sensing lines. The primary and secondary float valves operate independently. 65. Fuel pressure applied to the fueling valve unseats the spring-loaded pistons and spills fuel into the fuel tank from the valve. At the same time fuel is fed through the pilot lines to the pilot valve. As long as the fuel level in the fuel tank is below the level of the pilot valve primary and secondary floats and the FUEL SHUT-OFF TEST switch is deenergized, these valves remain open and the fuel is spilled into the fuel tank. However, when the fuel level in the fuel tank reaches the pilot valve and raises the primary or secondary float, the escape of fuel into the fuel tank is cut off and pressure in the lines builds up. As pressure in the pilot lines increases it acts on the back side of the fueling valve pistons. When the fuel pressure on both sides of either piston is equal, the springs, which hold the pistons closed in the no-pressure condition, act to close the fueling valve. The fuel flows out the vent outlets in case of a failure of the primary and secondary float valve or fueling valve. This keeps pressure in the fuel tank below the allowable limit during fuel transfer operation. 66. During defueling operation the fueling valve operates in the same manner as during the fueling operation with the following exception. When defueling pressure is applied to the fueling valve, suction bleed flow from behind the two poppets is drawn through individual passages, each fitted with a check valve. The suction bleed flow creates a partial vacuum (negative gauge pressure) behind the poppets. The poppets open when a suction pressure of 10.0 inch Hg (-5.5 psig) is applied to the fueling valve. After defueling flow is established a substantially lesser suction pressure will suffice to hold the fueling valve open. The pilot valve has no function in defueling except that it contains check valves which prevent air from being drawn backwards through the pilot valve bleed lines and spoiling the partial vacuum behind the fueling valve poppets.
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Page 45 67. FUEL TANK VENT VALVE. Vent valves, located adjacent to the pilot valves and accessible in the same manner as the pilot valves, are installed in each fuel tank. These valves are connected overboard through individual vent lines to permit normal fuel tank venting. The vent valves prevent fuel overflow or siphoning through the vent lines during normal aircraft maneuvering. The vent line for each wing fuel tank terminates at a flush outlet in the wing lower surface inboard of the wingtip and forward of the aileron. The fuselage cell and center section fuel tank vent lines connect in the center section fuel tank to a common vent line which terminates at a flush outlet adjacent to the left wing fuel tank overboard vent outlets. An overboard drain line is provided at the low point in the line, at approximately WS 66. The drain line terminates in an overboard drain mast forward of the flaps at approximately WS 105. At WS 58, a bypass vent line with check valve is plumbed to the wing trailing edge terminating in a flush ram scoop. The check valve is installed at the bypass juncture with the main vent line preventing air overflow through the bypass vent line. Air inflow through the vent bypass line in flight provides positive pressure in the bladder cell, preventing bladder cell collapse. Excessive positive pressure vapor is discharged overboard clear of the aircraft through these vent openings which are designed to minimize the possibility of icing.
68. Each vent valve contains a float-actuated poppet, a suction relief valve and two pressure relief valves. The weight of the float keeps the poppet open until the fuel level rises and forces the float up. When the float rises, the poppet closes. With the poppet closed, the pressure relief valve opens at 1.20 0.10 psi minimum to relieve fuel tank pressure. This suction relief valve opens at 0.10 psi minimum.
69. FLOAT VENT VALVE, P-3C AIRCRAFT BUNOs 161129 AND SUBSEQUENT AND P-3A, P-3B AND P-3C AIRCRAFT INCORPORATING AFC 392. The existing fuel venting system is modified for No. 1 and No. 4 fuel tanks. A float-operated pressure relief valve (float vent valve) and a larger vent line are added. The float vent valve is located aft of the vent valve. A new Y-configured 1.5/2.5 inch vent tube is added. The 1.5 inch tube segment connects to the vent valve and the 2.5 inch segment connects to the float vent valve. A single 2.5 inch line vents overboard through a new 2.5 inch flame arrestor.
Change 2 - 1 July 1998 70. The float vent valve contains two floats and a pressure-operated relief valve. The weight of the floats keeps the relief valve open until the fuel level rises and forces the relief valve closed. With the relief valve closed, the relief valve opens at a cracking pressure 1.5 psi minimum differential pressure to relieve fuel tank pressure. 71. NO. 5 FUEL TANK PRESSURE GAUGE, P-3C AIRCRAFT BUNOs 161129 AND SUBSEQUENT AND P-3A, P-3B AND P-3C AIRCRAFT INCORPORATING AFC 392. A fuel tank pressure-monitoring and overpressurization system is added for No. 5 fuel tank. A pressure gauge is added near the fueling control panel (Figure 3) and connected to No. 5 fuel tank. 72. The No. 5 fuel tank pressure gauge incorporates a single black pointer or bar. The area behind the bar is divided into a green and a red area. The green area covers the movement of the bar between 0 and 7.0 psi (safe). Above 7.0 psi the bar is in the red area (fuel tank overpressurized) and latches at the highest pressure sensed. When this occurs, the gauge shall be replaced and the No. 5 fuel tank shall be inspected for structural damage. 73. RECIRCULATION LINE RELIEF VALVE. A fuel recirculation line is installed in No. 2 and No. 3 fuel tanks to provide a fuel tank overpressure protection for these fuel tanks in case of a failed shutoff valve during fuel transfer from the No. 5 fuel tank. The recirculation line exits from the No. 5 fuel tank and extends outboard to approximately WS 202 where it terminates in a pressure relief valve which opens at a minimum pressure of 1.20 0.10 psi. 74. PRESSURE CONTROL VALVE. A pressure control valve is mounted at the discharge of each of the fuselage cell transfer pumps. The valve is designed to bypass excess fuel pump flow to maintain an approximately constant static pressure at the pump discharge. Excess fuel flow is bypassed directly to the fuselage fuel cell. The valve opening pressure is 10.5 psi minimum and reclosing pressure is 11.5 1.0 psi. 75. TRANSFER PUMP. Two transfer pumps are installed in the fuselage cell at FS 490 and FS 542 on the aircraft centerline. These are dual element pumps consisting of a scavenge element and a transfer element. The purposes of the transfer pumps is to transfer fuel out of the fuselage cell to the engine feed fuel tanks.
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Page 46 76. The scavenge element draws fuel from the center section fuel tank to the fuselage cell. The transfer element supplies fuel from the fuselage cell through the pressure fueling manifold to the engine feed fuel tanks. Nominal rating of the transfer element is 5000 pounds per hour flow at 18 psi discharge pressure. The mean average flow rate of the scavenger element at the inlet is 2500 pounds per hour. Discharge pressure is controlled by the pressure control valve. A thermal switch opens when the motor case temperature exceeds 204.4_C (400 _F) which interrupts power to the motor, preventing overheating. To reset the thermal switch, the pump must be removed and packed in dry ice. The transfer pumps are installed on small cover plates. These cover plates are accessible on the bottom of the fuselage fuel cell. Transfer pump elements are directly interchangeable with the boost pump elements. The discharge scroll housings are not interchangeable.
77. BOOST PUMP. Four boost pumps are used in the fuel system, one installed in each engine feed fuel tank. The boost pumps are located in the surge boxes at approximately WS 75 and WS 228 (left and right). Small access cover plates are located in the wing upper panel directly over the pumps. The fuel tanks need not be completely drained for pump removal. It is necessary to defuel the fuel tank to approximately 3250 pounds of fuel remaining. The fuel is then below the level of the access hole in the upper wing panel which must be opened to remove the pump.
78. Each boost pump is a dual element pump consisting of a scavenge element and a boost element. The scavenge element supplies fuel to the surge box maintaining a flooded surge box condition. The boost element draws fuel from the surge box and supplies it to the engine-driven fuel boost pump. The boost element has a nominal rating of 5000 pounds per hour flow at 18 psi discharge pressure. The scavenge element nominal rating is 2000 pounds per hour flow at 5 psi discharge pressure. The motor is prevented from overheating by a thermal switch which opens when the motor case temperature exceeds 204.4 _C (400_F) which interrupts power to the motor.
79. Boost pumps have a quick-disconnect type joint between the pumping element and the discharge
Change 2 - 1 July 1998 casing. The discharge casing is bolted to the bottom of the fuel tank. The pumping element is removed from the fuel tank through the overhead access opening. Boost pump elements are interchangeable with the transfer pump elements. However, the discharge scroll housing is not interchangeable. 80. DUMP PUMP, AIRCRAFT BUNOs 153442 AND SUBSEQUENT AND AIRCRAFT INCORPORATING AFC 188. The fuel dump pump located in No. 5 fuel tank is a fuel tank-mounted, submerged, 200 volt, 400 Hz electric motor driven fuel transfer pump. The motor-impeller section of the pump is a plug-in design which inserts into the scroll housing. The scroll housing is mounted to the fuel tank structure by means of a support bracket installation. Removal of the motor-impeller assembly is performed by use of a special tool. 81. PRESSURE SWITCH. Discharge pressure of the fuel boost and fuel transfer pumps is sensed by pressure switches. The contacts of the switches close on decreasing pressure which completes a circuit to low pressure warning advisory lights in the flight station FUEL MANAGEMENT panel. The boost pump pressure switches are installed on the wing rear beam adjacent to the boost pumps. Contacts of boost pump pressure switches close on decreasing pressure at 2.00 0.25 psig and open on increasing pressure at 3.50 0.25 psig. The transfer pump pressure switches are located on the FS 553 bulkhead at approximately BL 11.0 l eft . Co nta cts of the tra nsf er p um p pr e ss ur e switches close on decreasing pressure at 3.00 0.25 psig and open on increasing pressure at 5.25 0.25 psig. 82. FUEL TANK SHUTOFF AND CROSSFEED SHUTOFF VALVES. Each engine feed fuel tank has an electrically operated fuel tank shutoff valve mounted in the wing front beam to shut off engine feed fuel. These valves are located at WS 128 and WS 266 (left and right). 83. A fuel crossfeed shutoff valve is plumbed between the fuel tank shutoff and emergency shutoff valves in each wing fuel tank. The valve is electrically operated and is identical to the fuel tank shutoff valve. These valves are located at WS 118 and WS 248 (left and right). An additional crossfeed shutoff valve is located at WS 92 left on the No. 2 wing fuel tank front beam. It controls fuel flow during crossfeed from one side of the aircraft to the other.
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Page 47 84. A split phase capacitor type motor operates the valve either open or closed. The motor drives limit switches in the valve actuator controlled by a double pole, double throw switch at the flight station center console FUEL MANAGEMENT panel.
85. When a shutoff switch on the FUEL MANAGEMENT panel is set to OPEN, the split phase motor is energized through a circuit breaker on the monitorable essential ac bus, the valve control switch and a motor-driven limit switch. This limit switch remains closed until the valve is fully open. A shutoff valve advisory light on the FUEL MANAGEMENT panel comes on through the valve control switch and another motor-driven limit switch which remains closed until the valve is fully open. When the valve is open, the light goes off. When the switch is set to CLOSE, the motor is energized and closes the valve. Closing is similar to opening with the exception that a different pair of limit switches is used to limit close travel and advisory light function. Thermal relief valves in the actuator relieve at 80 to 100 psi and reseat at 50 psi minimum.
86. Accessible behind the hinged leading edge panels of the wing is the valve body which plugs into the valve housing. The valve housing is mounted inside the fuel tank on the wing front beam. An indexing pin and positioning screw anchor the valve in place in the housing. Defueling is not necessary for valve body removal. Turning the valve before unplugging closes the ports preventing fuel spillage. Electrically operated fuel tank shutoff valves and crossfeed shutoff valves are identical and may be interchanged.
87. DUMP VALVE, AIRCRAFT BUNOs 153442 AND SUBSEQUENT AND AIRCRAFT INCORPORATING AFC 188. The fuel dump valve is located on the rear beam aft of the No. 2 fuel tank. It is an electric motor-operated gate-type fuel shutoff valve with a bolted flange type mounting and has a 2 inch line size. The valve is designed for an operating pressure of 60 psi, proof pressure of 150 psi and a burst pressure of 225 psi.
88. The sealed actuator is capable of with sta ndi ng 1 5 ps i i nter n al pr es su res . The actuator is a 28 vdc split
Change 2 - 1 July 1998 series wound, intermittent duty, motor driven unit incorporating planetary reduction gearing, a clutch and internal cutout limit switches. The actuator bolts directly to the valve body and is connected to the gate actuation arm by means of a split shaft which provides actuator removal without disassembly or adjustment of the valve or actuator. The valve operates in 1 second (or less) at 28 vdc at a maximum loading of 60 psi. 89. EMERGENCY SHUTOFF VALVE. Each engine feed fuel tank has an emergency shutoff valve installed through the wing front beam. Location of these valves is at WS 146 and WS 302 (left and right). When closed, the emergency shutoff valves prevent fuel from reaching the engines through the engine fuel feed system. Operation of the emergency shutdown handle in the flight station results in mechanical closure of the valve. 90. The valve assembly is accessible behind the hinged leading edge panels of the wing and consists of a housing mounted within the fuel tank and a v alv e body which plugs into the housing. An indexing pin and positioning screw anchor the valve in place in the housing. The valve body is removed without defueling by first turning the valve body to close the ports in the housing and then unplugging the valve body. The housing, mounted in the fuel tank, is identical to the crossfeed and fuel tank shutoff valve mount housings. 91. CROSSFEED THERMAL RELIEF VALVE. A pressure relief valve is located in the fuel crossfeed manifold to the left of the centerline in the center section fuel tank area. Fuel normally remains in the manifold and expansion of this fuel due to temperature change is relieved through the relief valve with excess fuel flowing into the center section fuel tank. The valve opening pressure is 45 5 psig and closing pressure 30 psig minimum. 92. DUAL CHECK VALVE. A dual check valve is installed at the outlet of each boost pump. The check valve permits use of a bypass line when the boost pump is not operating, by taking fuel from the same screen as the boost pump. The valve is mounted in the surge box and is connected between the boost pump outlet and the screen assembly. The check valve prevents fuel from transferring from one fuel tank to another during fuel crossfeed if the shutoff valves fail to close. A drain hole in the pressure port of the valve permits relief from the feed line into the fuel tank when temperature expansion occurs.
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Page 48 93. In the fuselage cell, a dual check valve is located at FS 553. Both transfer pumps discharge through plumbing to this check valve. The transfer pumps are paralleled and the check valve prevents fuel feedback through a failed pump. During pressure fueling, the fuel flow is directed through the fueling manifold and prevented from circulating through the transfer pump discharge lines by the dual check valve. Check valves are accessible for servicing through the fuel tank manhole.
94. INTERCONNECT CHECK VALVE. The interconnecting hose between the center section fuel tank and the fuselage cell feeds fuel to the fuselage cell through a caged ball-check valve mounted in the fuselage cell.
95. The caged ball rolls to, and remains in, the full open position when the longitudinal centerline of the valve cage is 2 degrees maximum below horizontal. When the valve cage longitudinal centerline is 2 degrees maximum above the horizontal with 1 to 50 inches of differential fuel head acting in the checked flow direction, the ball rolls to, and remains in, the closed position. The valve is mounted in the fuel tank at a 4 degree forward slope from horizontal. Thus, the ball closes and checks fuel flow when the aircraft attains a 6 degree or more climb attitude.
96. An overflow standpipe mounted in the fuselage cell ports into the interconnect on the center section fuel tank side of the check valve. If more fuel is entering the fuselage cell through pump scavenge lines than is being used by the transfer pumps, the fuselage cell could overpressurize. A fuel level is established by the overflow standpipe to prevent excess pressure in the fuselage cell. Excess fuel flows through the standpipe and back to the center section fuel tank.
97. FUEL TANK DRAIN VALVE. Drain valves are provided in the bottom of each fuel tank to allow drainage of water or residual fuel. The fuselage cell has one drain valve at approximately FS 480 on the aircraft centerline. The center section fuel tank has drain valves at approximately FS 627, WS 59 (left and right). Left and
Change 2 - 1 July 1998 right wing fuel tank drain valves are at approximately WS 70 and WS 226. 98. The drain valves mount flush in the fuel tanks. A force of 7 to 13 pounds on the drain valve causes the valve to open. The valves are self-closing and have no provisions for being locked. 99. Primary valve seats can be replaced without first defueling the fuel tanks. When the bottom plate is removed, the spring-loaded valve drops down and is sealed by the secondary seal allowing the exposed seal to be replaced. 100. SIGHT GAUGE. A sight gauge is provided in the center section fuel tank allowing fuel quantity measurement of the No. 5 fuel tank from the ground (Figure 16). The sight gauge is located at approximately FS 621, BL 4 left. 101. The sight gauge assembly consists of an inner housing which acts as a guide for the slip tube, an outer housing and the slip tube. The slip tube is a lucite rod with a bonded quartz tip mounted in an aluminum tube. A packing between the viewing plate and other housing seals the tube assembly. The sight gauge mount housing is equipped with a spring-loaded flapper valve which closes to prevent fuel spillage when the sight gauge is removed for maintenance. 102. Fuel quantity in the No. 5 fuel tank is read on the slip tube assembly. Light reflected up the lucite rod is diffused in the fuel tank. As the quartz tip of the rod is pulled down into the fuel, reflected light absorption by the fuel results in the viewing plate becoming dark. The quantity of fuel reading is made on the slip tube. 103. FUEL TANKS.
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Page 49 ribs and the upper and lower integrally stiffened, milled skin panels form the fuel tanks. Ribs at the end of the fuel tanks are solid bulkheads. The ribs within the fuel tanks are open truss structure with upper and lower caps clipped to the integral stiffeners of the wing panels. Gaps between the rib caps and the skin are not sealed, allowing fuel to flow to the lowest part of the fuel tank. All faying surfaces in the fuel tank area, through which fuel could leak to the outside, are sealed. Each wing fuel tank contains a surge box in the aft inboard corner. The wing rear beam and the fuel tank inboard bulkhead form two sides of the surge box.
106. Wing fuel tanks contain plumbing for fueling, fuel crossfeeding, venting and engine fuel feed. No. 2 and No. 3 inboard wing fuel tanks contain a recirculation line to the center section fuel tank. All plumbing is secured by brackets to the fuel tank walls, wing rib caps and diagonals. A pilot valve at the fuel tank high point controls the fueling valve located on the wing rear beam in each fuel tank. Fuel tank shutoff valves, engine feed, emergency and crossfeed valves are located in the applicable plumbing at the front wall of the fuel tank. The boost pump, screen and the dual check valve are in the surge box. Vent lines from the vent valves lead outboard to the overboard vents. Overwing and underwing openings, having sealed doors, are provided for access to fuel tank interiors. Overwing fillerwells are provided in each wing fuel tank.
104. WING FUEL TANKS. The four wing fuel tanks are engine feed fuel tanks (Figures 13 and 14). Each fuel tank supplies fuel to its respective engine. The fuel tanks are numbered from left to right facing forward, No. 1, No. 2, No. 3 and No. 4. No. 2 and No. 3 inboard fuel tanks extend outward from WS 65 to WS 221 (left and right) and No. 1 and No. 4 outboard fuel tanks extend from WS 221 and WS 584 (left and right). 105. The fuel tanks are integral with the wing structure. The front and rear wing beams, wing
107. CENTER SECTION FUEL TANK. The center section fuel tank is constructed integral with the wing, is located between FS 571 and FS 694 and extends outward to WS 65 (left and right) (Figures 13 and 14). The front and rear wing beams, ribs and the upper and lower, integrally stiffened, milled skin panels form the fuel tank. The center section skin panels are unbroken through the center section span, except for access openings in the lower surfaces. The wing ribs at WS 65 are solid bulkheads.
108. A dome in the top of the fuel tank houses the vent and pilot valves. The pilot valve controls operation of the fueling valve located at the fuel tank front wall. Plumbing in the center section fuel tank includes: the cross ship crossfeed line with a thermal relief valve, transfer lines, vent line with bypass line and a Y-fitting through the rear wall of the fuel tank connecting the fueling manifold to the fueling adapters in the right wing fillet.
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Figure 16.
Sight Gauge - Optical Fuel Indication
003016
Change 2 - 1 July 1998 109. FUSELAGE FUEL CELL. The fuselage fuel bladder cell is mounted within the fuselage forward of the wing front beam in an unpressurized area between FS 447 and FS 553, extending down from WL 117 to a fiberglass liner near the fuselage skin. 110. The fuel cell is of rubber and cloth construction, supported on each end and side by metal structural walls and on the bottom by a fiberglass liner supported by structural rings and longerons and nonstructural stiffeners. The top of the fuel cell is of drape-type construction with a nylon cord and bonded fuel tank loop support system. The sides, ends and bottom of the fuel tank use a nylon cord support system to prevent shifting and collapse of the cell under negative pressures. The fuel tank and support system are designed to withstand a pressure differential of 1 psi acting to collapse the fuel tank. The fuel tank vent system limits this pressure to approximately 0.25 psi under emergency descent with normal operation of the float vent valves. A 10 by 18 inch oval manhole for interior access is located on the bottom of the fuel cell at the aft end. 111. Equipment installed in the fuel cell includes two transfer pumps discharging to a dual check valve at the fueling manifold, two transfer pressure control valves, a fueling valve controlled by a pilot valve, a standpipe aft of the ball check valve at
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Page 51/(52 Blank) the interconnect to the center fuel tank, a vent valve and a drain valve. 112. FUEL (BLADDER) CELL DRAIN MAST. The fuel (bladder) cell drain mast (mast) is an airfoilshaped hollow drain tube located along the lower fuselage centerline at FS 524. The mast is constructed of fiberglass cloth preimpregnated with polyester resin. The mast upper end flares to form a flange, by which the mast attaches to the aircraft. The flange is secured by four fastener studs and a hinge assembly. 113. The mast performs three functions. It evacuates fumes from the bladder cell compartment (surrounding the bladder cell), directs fuel leaking from the bladder cell or cell compartment away from the aircraft and increases the pressure between the inside and outside of the bladder cell. This third function helps hold the cell against the cell compartment walls to prevent chafing of the cell from normal vibrations. 11 4 . E X P L O S I O N S U P P R E S S A N T F O A M BAFFLE SYSTEM. All fuel tanks may be equipped with the explosion suppressant foam baffle (foam baffle system). The foam baffles are constructed of polyurethane reticulated foam. Reticulated foam is used in fuel tanks to reduce the probability of fire or explosion in the event of damage from combat or crash.
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ORGANIZATIONAL MAINTENANCE SYSTEM MAINTENANCE AIRCRAFT FUEL SYSTEM Reference Material Confined Space (Fuel Tank) Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 008 00 Aircraft Fuel Cells and Internal/External Fuel Tanks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . NAVAIR 01-1A-35 General Information and Servicing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . NAVAIR 01-75PAA-2-1 Aircraft Handling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 009 00 Line Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 010 00 Fueling System Servicing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 011 00 Airframe Group . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . NAVAIR 01-75PAA-2-2 Powerplant Related Electrical Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . NAVAIR 01-75PAA-2-30 Structural Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . NAVAIR 01-75PAA-3-1 Powerplant Related Electrical Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . NAVAIR 01-75PAC-2-13.1.2 Aircraft Refueling for Shore Activities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . NAVAIR 06-5-502 Alphabetical Index Subject Component Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . No. 5 Fuel Tank Pressure Gauge Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . No. 5 Fuel Tank Pressure Gauge Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Pressure Fueling Adapter Valve Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Pressure Fueling Adapter Valve Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Wiggins-Type Fuel Line Interconnect Coupling Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Wiggins-Type Fuel Line Interconnect Coupling Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Wiggins-Type Fuel Line-to-Component Coupling Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Wiggins-Type Fuel Line-to-Component Coupling Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Functional Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fuel Dump System Functional Check (Dry), Aircraft BUNOs 153442 and Subsequent and Aircraft Incorporating AFC 188 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Operational Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Defueling System Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fuel Crossfeed System Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fueling System Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Procedures Covered In Other Manuals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fuel Leak Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Wing Fuel Tank Access Cover Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Record of Applicable Technical Directives Type/No. AFC 188 AFC 578 Date 2 Mar 70 Title and ECP No. AIRFRAME: Increased Gross Weight and Fuel Dump Capability (ECP 494) SUSTAINED READINESS PROGRAM (SRP) Date Inc. 15 Dec 70 15 Aug 98 Remarks Page No. 10 21 19 19 16 13 10 15 15 7 7 2 5 6 2 2 8 8 10
Change 2 - 1 July 1998 1. PROCEDURES COVERED IN OTHER MANUALS. 2. The following servicing procedures are covered in NAVAIR 01-75PAA-2-1: fuel system servicing, fueling precautions, single point pressure fueling, overwing fueling and defueling. 3. Fuel system maintenance safety procedures are covered in NAVAIR 06-5-502 and NAVAIR 01-1A-35. 8. Preparation.
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Support Equipment Required
Nomenclature
Type Designation/ Part No. CAGE
NOTE
NAVAIR 01-1A-35 shall be used in conjunction with and in support of fuel system maintenance procedures contained in this manual. However, if there is a conflict between NAVAIR 01-1A-35 and the maintenance procedures contained in this manual, NAVAIR 01-1A-35 shall take precedence. Before refueling the fuel tank after total defuel (dry fuel tank) to repair a fuel leak, the applicable fuel tank master and repeater fuel quantity indicators must read zero. If the indicators do not read zero, the fuel quantity indicating system is out of tolerance and shall be dry fuel tank calibrated. Refer to NAVAIR 01-75PAC-2-13.1.2 and NAVAIR 01-75PAA-2-30. 4. Refer to NAVAIR 01-75PAC-2-13.1.2 and NAVAIR 01-75PAA-2-30 for fuel quantity indicating system maintenance and WP 008 00 of this manual for use of explosive gas detector (part of 72-8001 explosive gas detector set). 5. The following maintenance procedures are covered in NAVAIR 01-75PAA-3-1: a. Integral fuel tank maintenance, including leak location and repair. b. Fuel tank access door maintenance. c. Main landing gear trunnion bolt maintenance. 6. OPERATIONAL CHECKS. 7. FUELING SYSTEM CHECK. This check verifies correct operation of fueling valves and fuel tank vents.
Source, Fuel Servicing Stand, Maintenance
B4A
98897
Fueling system servicing safety procedures shall be observed during system operational check. Refer to NAVAIR 06-5-502.
NOTE
The aircraft shall be laterally level with a 1 degree nosedown attitude throughout the check. a. Position aircraft in a 1 degree nosedown attitude and laterally level (NAVAIR 01-75PAA-2-1, WP 009 00). b. Open fueling control panel access door and check that all switches are set to OFF or CLOSED.
Before applying power, all electrical access panels shall be closed and personnel alerted that power will be applied. c. Apply power to aircraft (NAVAIR 01-75PAA-2-1, WP 010 00). d. AIRCRAFT NOT INCORPORATING AFC 578: Verify indicators come on when INDICATOR LIGHTS test switch is pressed. (QA) (1) AIRCRAFT INCORPORATING AFC 578: Verify indicators come on when INDICATOR LIGHT test switch is pressed. (QA)
Change 2
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Page 3 line on No. 5 fuel tank pressure gauge, fueling shall be halted immediately and a visual inspection of No. 5 fuel tank shall be accomplished prior to any flight. b. If applicable, monitor No. 5 fuel tank pressure gauge to prevent fuel tank overpressurization. Open fueling nozzles and apply 8 to 12 psi fueling pressure. All six VALVE CLOSED INDICATION indicators may go off momentarily but must come on within 4 seconds.
NOTE
For greater accuracy, fuel tanks should be defueled before start of check. e. Remove fueling adapter seal caps and connect fueling-defueling hoses. 00). f. Defuel aircraft (NAVAIR 01-75PAA-2-1, WP 011
9. Check. Support Equipment Required Type Designation/ Part No. CAGE B4A 98897 Fuel supply pressure shall not exceed 55 psi. c. Increase fueling pressure to 50 5 psi. All six VALVE CLOSED INDICATION indicators must remain on. d. Record time at start of check so elapsed time to fuel the aircraft can be determined. e. Set six FUELING VALVE CONTROL SWITCHES to OPEN. All six VALVE CLOSED INDICATION indicators shall go off.
Nomenclature Source, Fuel Servicing Stand, Maintenance
Materials Required Nomenclature Specification/ Part No.
Turbine Fuel, Aviation, JP-4 or JP-5 MIL-T-5624 Turbine Fuel, Aviation, JP-8 MIL-T-83133A a. On fueling control panel, set SYSTEM POWER switch to ON. All six VALVE CLOSED INDICATION indictors shall come on. Positive fuel tank venting shall occur throughout fueling procedure. Fueling procedure shall be stopped and investigated if airflow is not felt. f. Verify all fuel tanks are venting. If, during pressure fueling cycle, any of the following events occur: wing fuel tank overfilled; wing fuel tank fuel spillage from a wing tip vent; or loud or unusual noise accompanied by wing vibration, fueling shall be halted immediately and an inspection of the internal wing structure (WS 380 through WS 465) for structural damage shall be accomplished prior to next flight. On P-3C aircraft BUNOs 161129 and subsequent and P-3A, P-3B and P-3C aircraft incorporating AFC 392, No. 5 fuel tank pressure gauge shall be monitored to prevent fuel tank overpressurization. If during pressure fueling cycle the black pointer contacts the overpressure indication
If VALVE CLOSED INDICATION indicators do not come on during primary or secondary fuel shutoff valve checks, fueling shall be discontinued and investigated.
NOTE
Time to perform primary and secondary fuel shutoff tests shall be recorded and subtracted from total fueling time, at end of check.
Change 2 g. After 5 minutes, set FUEL SHUT-OFF TEST switch to PRIMARY and record time. All six VALVE CLOSED INDICATION indicators must come on within 15 seconds. h. Verify fuel quantity gauges on fueling control panel or flight station FUEL MANAGEMENT panel and record individual fuel tank and total fuel tank fueling rates. Average fueling rate shall be 600 gallons per minute (gpm) with both fueling adapters in use.
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Page 4 m. As individual fuel tanks reach full level, pilot valves operate to close fueling valves and respective VALVE CLOSED INDICATION indicators come on. n. Record time as each fuel tank VALVE CLOSED INDICATION indicator comes on. o. Sum recorded times required to perform primary and secondary fuel shutoff tests. Subtract sum of test times from total fueling time. p. Verify that total time to simultaneously fill the five fuel tanks with approximately 9200 U.S. gallons of fuel does not exceed 20 minutes. All five fuel tank shutoff valves must shut off within a 1.5 minute interval. q. Check fuel quantity in No. 5 fuel tank using fuel sight gauge in center section fuel tank. Gauge should indicate a quantity of approximately 2646 U.S. gallons. 10. Conclusion.
NOTE
Individual fuel tank fueling rates (in gpm) should be: No. 1 or No. 4 fuel tank: 95 to 115 No. 2 or No. 3 fuel tank: 100 to 120 No. 5 fuel tank: 160 to 180 When the total time to simultaneously fill the five fuel tanks with approximately 9200 U.S. gallons of fuel does not exceed 20 minutes and all five fuel tank shutoff valves shut off within a 1.5 minute interval, the specified individual fuel tank fueling rates need not be met. i. Set FUEL SHUT-OFF TEST switch to OFF and then to SECONDARY. All six VALVE CLOSED INDICATION indicators may go off momentarily and then come on. j. Set FUEL SHUT-OFF TEST switch to OFF. Record time. All six VALVE CLOSED INDICATION indicators must go off and fueling should continue. k. Monitor fuel quantity gauges and at 9000 pounds of fuel in No. 1, No. 2, No. 3 or No. 4 fuel tank, or 15000 pounds of fuel in No. 5 fuel tank, again test secondary pilot valve shutoff of fueling valves by setting FUEL SHUT-OFF TEST switch to SECONDARY. Within 15 seconds, all six VALVE CLOSED INDICATION indicators must come on. Record time. l. Set FUEL SHUT-OFF TEST switch to OFF. Within 15 seconds, all six VALVE CLOSED INDICATION indicators must go off. Record time.
a. Set all six FUELING VALVE CONTROL SWITCHES to CLOSED and SYSTEM POWER switch to OFF. b. Remove fueling pressure; disconnect fueling nozzles from fueling adapters and install seal caps on adapters. c. Close fueling control panel access door.
d. Remove power from aircraft (NAVAIR 01-75PAA-2-1, WP 010 00). 11. DEFUELING SYSTEM CHECK. This check verifies correct operation of fueling valves and fuel tank vents. 12. Preparation. Support Equipment Required Nomenclature Source, Fuel Servicing Stand, Maintenance Type Designation/ Part No. CAGE B4A 98897
Change 2
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Page 5 (1) AIRCRAFT INCORPORATING AFC 578: Verify indicators come on when TEST switch is pressed. (QA)
Fuel system servicing safety procedures shall be observed during system operational check. Refer to NAVAIR 06-5-502.
NOTE
For greatest accuracy, fuel tanks should be full at start of check. f. Remove fueling adapter seal caps and connect defueling hoses. 13. Check.
NOTE
The aircraft shall be laterally level with a 1 degree nosedown attitude throughout the check. a. Position aircraft in a 1 degree nosedown attitude and laterally level (NAVAIR 01-75PAA-2-1, WP 009 00).
Support Equipment Required Type Designation/ Part No. CAGE B4A 98897
Nomenclature Before applying power, all electrical access panels shall be closed and personnel alerted that power will be applied. b. Apply power to aircraft (NAVAIR 01-75PAA-2-1, WP 010 00). c. Open fueling control panel access door and verify that all switches are set to OFF or CLOSED. d. Check fuel quantity gauges and record fuel quantities for use in determining defueling rate. e. AIRCRAFT NOT INCORPORATING AFC 578: Verify indicators come on when INDICATOR LIGHTS test switch is pressed. (QA) Container, Safety, Fuel, 5 gal Source, Fuel Servicing Stand, Maintenance
If air inflow to fuel tank vents is not felt throughout defueling check, defueling shall be stopped and investigated. a. Monitor No. 5 fuel tank vent outlet in mast at WS 58L (left) in addition to wingtip vent outlets for air inflow to fuel tanks during entire defueling check.
b. Set all six FUELING VALVE CONTROL SWITCHES to OPEN. c. At fueling control panel, set SYSTEM POWER switch to ON. All six VALVE CLOSED INDICATION indicators must come on. d. Record time at start of defueling procedure so elapsed time to defuel can be determined. 14.
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NOTE
After defueling, the amount of fuel remaining in each of No. 1, No. 2, No. 3 and No. 4 wing fuel tanks should not exceed 10 gallons; in fuselage bladder cell, 20 gallons; and in wing center section fuel tank, 15 gallons. Conclusion.
a. Set FUELING VALVE CONTROL SWITCHES to CLOSED and SYSTEM POWER switch to OFF. b. Relieve defueling pressure and disconnect defueling nozzles from fueling-defueling adapters. If air inflow to fuel tank vents is not felt throughout defueling check, defueling shall be stopped and investigated. e. Set SYSTEM POWER switch to ON and apply defueling suction pressure of 10 inches Hg vacuum (-5.5 psi). VALVE CLOSED INDICATION indicators must come on. Record time. f. Monitor fuel quantity gauges on fueling control panel and determine defueling rate during a 5 minute period. c. Install adapter seal caps and close fueling control panel access door. d. Remove power from aircraft (NAVAIR 01-75PAA-2-1, WP 010 00). 15. FUEL CROSSFEED SYSTEM CHECK. This check verifies correct operation of crossfeed valve, main fuel tank valve and boost pump corresponding to crossfeed system for one engine only.
NOTE
The minimum defueling rate is 150 gpm at a negative pressure of 10 inches Hg (-5.5 psi). g. At completion of defueling, record time. Fuel system servicing safety procedures shall be observed during system operational check. Refer to NAVAIR 06-5-502.
NOTE
The time to defuel all fuel tanks should not exceed 65 minutes.
NOTE
Perform following check for all engines only when operational integrity of entire system is required. Replacement of crossfeed system component only requires operational check of crossfeed system for corresponding engine. 16. Preparation.
TURBINE FUEL, AVIATION
1 Before applying power, all electrical access panels shall be closed and personnel alerted that power will be applied.
h. Drain remaining fuel in each fuel tank into safety fuel containers and determine quantity of residual fuel after defueling each fuel tank.
a. Apply power to aircraft (NAVAIR 01-75PAA-2-1, WP 010 00). b. Verify that fuel quantity gauges on FUEL MANAGEMENT panel corresponding to crossfeed system for engine being tested indicates approximately 1300 pounds of fuel. c. Verify that all switches on flight station FUEL MANAGEMENT panel are set to OFF or CLOSED and no pressure is indicated on crossfeed pressure indicator. 17. Check. 18. Conclusion.
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a. Check that all switches on FUEL MANAGEMENT panel except MAIN TANK VALVE switches are set to OFF or CLOSE. b. Set MAIN TANK VALVE switches to OPEN. c. Remove power from aircraft (NAVAIR 01-75PAA-2-1, WP 010 00). 19. FUNCTIONAL CHECK.
NOTE
The following step is applicable when testing crossfeed system for No. 1 or No. 2 engines only. a. Set center section CROSSFEED valve switch to OPEN; X-FEED indicator light momentarily comes on and then goes off. b. Set crossfeed switch to OPEN; X-FEED indicator light momentarily comes on and then goes off. c. Set BOOST PUMP switch to ON; verify BOOST low-pressure caution light goes out and no pressure is indicated on crossfeed pressure indicator. d. Set CROSSFEED switch to CLOSE; set main tank switch to OPEN. TANK indicator light momentarily comes on and then goes off. Verify pressure is indicated on crossfeed pressure indicator.
20. FUEL DUMP SYSTEM FUNCTIONAL CHECK (DRY), AIRCRAFT BUNOs 153442 AND SUBSEQUENT AND AIRCRAFT INCORPORATING AFC 188. This check verifies the correct operation of the fuel dump system. 21. Preparation.
a. Defuel No. 5 fuel tank (NAVAIR 01-75PAA-2-1, WP 011 00).
Before applying power, all electrical access panels shall be closed and personnel alerted that power will be applied. b. Apply power to aircraft (NAVAIR 01-75PAA-2-1, WP 010 00). c. At main load center on MAIN DC BUS circuit breaker panel, open and tag FUEL DUMP VALVE circuit breaker. d. Verify FUEL DUMP CONT circuit breaker on MAIN DC BUS circuit breaker panel at main load center is closed. e. Verify FUEL TRANSFER PUMP CONT FWD and AFT circuit breakers on EXTENSION MAIN DC BUS circuit breaker panel at forward load center are closed.
NOTE
The following step is applicable when testing crossfeed system for No. 1 or No. 2 engines only. e. Set center section CROSSFEED switch to CLOSE; set CROSSFEED switch to OPEN. Verify pressure is indicated on crossfeed pressure indicator. Set CROSSFEED switch to CLOSE; set center section CROSSFEED switch to OPEN. f. Set CROSSFEED switch to OPEN. Verify pressure is 15 to 30 PSI on crossfeed pressure indicator. g. Set BOOST PUMP switch to OFF, center section CROSSFEED switch to CLOSE, CROSSFEED switch to CLOSE, and MAIN TANK switch to CLOSE.
f. Verify FWD FUEL TRANSFER PUMP circuit breakers on MAIN AC BUS A forward circuit breaker panel and AFT FUEL TRANS PUMP circuit breaker on MAIN AC BUS B forward circuit breaker panel at main load center are closed. 22. Check. a. Verify FUEL DUMP PUMP circuit breaker on MAIN AC BUS A aft circuit breaker panel at main load center is closed. b. Verify FUEL DUMP switch on flight station fuel dump panel is set to OFF. c. Verify FWD and AFT fuel transfer pump control switches are set to OFF. (QA) d. Verify (visually) fuel dump valve is in closed position. (QA) k. 23. Leave switch set to OFF.
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Conclusion. a. Remove tags and close all circuit breakers.
b. Remove power from aircraft (NAVAIR 01-75PAA-2-1, WP 010 00). 24. TROUBLESHOOTING.
25. FUEL LEAK CHECK. A fuel leak is classified according to the quantity of fuel escaping (Figure 1). Fuel leak classes are: slow seep (stain), seep, heavy seep, dripping leak and running leak. 26. Confined Areas. Confined (closed) areas are: a. Wing front spar and leading edge. b. Nacelles above wing. c. All fillet enclosed areas (nacelle, fuselage and lower fuselage-to-wing fillet).
Fuel transfer and fuel dump pumps are not to be run dry over 30 seconds. Longer running could cause damage to pumps. e. Set FUEL DUMP switch to ON. f. Verify (audibly) that forward and aft fuel transfer pumps and the fuel dump pump operate. (QA) g. Set FUEL DUMP switch to OFF. h. Open and tag FWD FUEL TRANSFER PUMP, AFT FUEL TRANS PUMP and FUEL DUMP PUMP circuit breakers. i. Remove tag and close FUEL DUMP VALVE circuit breaker. j. Verify (visually) fuel dump valve opens when FUEL DUMP switch is set to ON and closes when switch is set to OFF.
d. All No. 5 fuel tank (center wing section) surfaces except lower surface not covered by lower fuselage to wing fillets. 27. Open Areas. The main landing gear wheel wells and the nacelles below the wing, even though enclosed, have an adequate exchange of air so that fumes from stains or seeps do not accumulate sufficiently to present a flight safety hazard. Open areas are: a. Wing rear spar and trailing edges outboard of fuselage. b. Nacelles below wing. c. Main landing gear wheel well (including landing gear fittings). d. Wing upper surfaces outboard of nacelles that are not covered by a fillet or a nacelle.
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Figure 1.
Fuel Leak Classification
004001
e. Wing lower surfaces outboard of fuselage that are not covered by a fillet. 32. WING FUEL LOCATIONS. TANK
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Page 10 ACCESS COVER
33. Wing fuel tank access covers and their location are shown in Figure 2. f. No. 5 fuel tank lower surface not covered by lower fuselage-to-wing fillets. 34. COMPONENT REMOVAL AND INSTALLATION.
35. WIGGINS-TYPE FUEL LINE INTERCONNECT COUPLING REMOVAL. Support Equipment Required Nomenclature Mask, Hose Blower Respirator, Air Line Set, Explosive Gas Detector Wrench, Spanner Type Designation/ Part No. CAGE AS02 GGG-M-125/1B, 81348 Type II 72-8001 51906
28. Stain. A stun is the slowest leak. It is characterized by a discoloration around fasteners or seams and is caused by a very slow fuel seepage which dries as it meets the air. A stain should be wiped off and, if it does not reappear within 1 hour, the location should be recorded and periodically inspected, unless it occurs in a confined area. (Refer to Confined Areas this WP.) If it occurs in a confined area, it should be repaired before next flight. If it occurs in an open area, repair is not required until the aircraft is removed from service for other maintenance requiring fuel tank entry.
29. Seep. A seep is a heavy stain which, when wiped off, reappears within one hour. This type of leak should be recorded and inspected frequently for increased activity. If it occurs in an open area, repair is generally not required until aircraft is temporarily removed from service for other maintenance requiring fuel tank entry. If seep occurs in a confined area it should be repaired before the next flight.
Power shall be disconnected from aircraft, static ground cable installed and external power switch tagged before performing fuel system maintenance. Refer to NAVAIR 01-1A-35. a. Remove power from aircraft (NAVAIR 01-75PAA-2-1, WP 010 00).
30. Heavy Seep. A heavy seep reappears immediately after being wiped off. It should be repaired prior to next flight when it occurs in an open area and shall be repaired before next flight if it occurs in a confined area.
31. Dripping and Running Leaks. A dripping leak is a continuous flow of fuel which wets a limited area and then drips off the aircraft. A running leak is continuous running of fuel caused by a definite break in the sealant or a defect in fitting. The source is usually easy to locate. These leaks shall be repaired before the next flight.
Personnel performing maintenance inside fuel tanks shall wear an air-supplied respirator at all times. Fresh air shall be circulated through the fuel tank while personnel are inside. Refer to NAVAIR 01-1A-35. No person shall enter a fuel tank unless certified safe for entry by an aviation gas free engineering technician (AVGFET). Refer to NAVAIR 01-1A-35.
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Figure 2.
Wing Fuel Tank Access Cover Locations (Sheet 1 of 2)
00400201
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Figure 2.
Wing Fuel Tank Access Cover Locations (Sheet 2)
00400202
b. Monitor atmosphere in fuel tank (WP 008 00).
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c. Remove lockwire from line coupling (Figure 3). Use spanner wrench to loosen coupling nut and coupling body.
d. body.
Loosen nut and separate coupling nut and
Power shall be disconnected from aircraft, static ground cable installed and external power switch tagged before performing fuel system maintenance. Refer to NAVAIR 01-1A-35. a. Verify that power is removed from aircraft, static ground cable is installed and external power switch is tagged.
e. Remove coupling retainer halves and line which has been disconnected.
f. Remove packing, split washers, coupling body and coupling nut from lines.
36. WIGGINS-TYPE FUEL LINE INTERCONNECT COUPLING INSTALLATION.
Personnel performing maintenance inside fuel tanks shall wear an air-supplied respirator at all times. Fresh air shall be circulated through the fuel tank while personnel are inside. Refer to NAVAIR 01-1A-35. No person shall enter a fuel tank unless certified safe for entry by an aviation gas free engineering technician (AVGFET). Refer to NAVAIR 01-1A-35. b. Monitor atmosphere in fuel tank (WP 008 00). c. Place coupling nut and coupling body over and behind tube beads of opposite line tubes with coupling threads facing tube ends. d. Place split washers over and behind tube beads.
Support Equipment Required Type Designation/ Part No. CAGE AS02 GGG-M-125/1B, 81348 Type II 72-8001 51906
Nomenclature Mask, Hose Blower Respirator, Air Line Set Explosive Gas Detector Wrench, Spanner Wrench, Torque, 0 to 150 lb-ins
PETROLATUM
Materials Required Specification/ Part No. MS20995C32 VV-L-236
e. Lubricate packings with petrolatum prior to installation on tubing. f. Place packings over and behind tube beads.
Nomenclature Lockwire Petrolatum
g. Place retainer halves on line tube ends with retainer shoulder between tube beads and packings. h. Slide coupling nut and coupling body together over retainer halves and engage threads.
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Page 14
Figure 3.
Wiggins-Type Line Coupling Removal and Installation
004003
i. Hold coupling body stationary and tighten coupling nut, using spanner wrench, to torque value specified in Table 1. (QA) Use line tube coupling size to determine correct torque value.
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Page 15 37. WIGGINS-TYPE FUEL LINE-TO-COMPONENT COUPLING REMOVAL. Support Equipment Required
NOTE
Coupling body torque values are same as coupling nut torque values. j. Lockwire coupling. (QA) k. Perform FUEL LEAK CHECK this WP. (QA) Table 1. Coupling Sizes Torque Value (+0, -1 PoundFeet) Nomenclature Wrench, Spanner Type Designation/ Part No. CAGE
a. Remove lockwire from line coupling (Figure 3). b. Use spanner wrench to loosen coupling nut (Table 1). c. Loosen coupling nut and separate from threaded boss. d. Remove split washers, packing and coupling nut. Discard packing. 38. WIGGINS-TYPE FUEL LINE-TO-COMPONENT COUPLING INSTALLATION. Support Equipment Required Nomenclature Wrench, Spanner Wrench, Torque, 0 to 150 lb-ins Type Designation/ Part No. CAGE
Coupling Size
Tube Size (Inches)
Spanner Part No.
Rigid Type -12D -16D -20D -24D -28D -32D -40D -48D -56D -64D 3/4 1 1 1/4 1 1/2 1 3/4 2 2 1/2 3 3 1/2 4 H9412A H9416A H9420A H9424A H9428A H9432A H9440A H9448A H9456A H9464A 7 13 18 30 32 33 35 62 80 90
Ratcheting Type -12D -16D -20D -24D -28D -32D -40D -48D -56D -64D 3/4 1 1 1/4 1 1/2 1 3/4 2 2 1/2 3 3 1/2 4 R9412A R9416A R9420A R9424A R9428A R9432A R9440A R9448A R9456A R9464A 7 13 18 30 32 33 35 62 80 90
Materials Required Nomenclature Lockwire Petrolatum Specification/ Part No. MS20995C32 VV-L-236
a. Place coupling nut (Figure 3) over and behind line tube bead with threads facing tube end.
b. Place split washer over and behind tube bead.
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PETROLATUM
Personnel and maintenance equipment shall be removed from operational area prior to operating flaps. b. Extend wing flaps for access to pressure switch (NAVAIR 01-75PAA-2-2). c. Remove power from aircraft (NAVAIR 01-75PAA-2-1, WP 010 00). d. At main load center on MAIN DC BUS circuit breaker panel, open and tag REFUELING MASTER SW circuit breaker. e. Open FUELING STATION ACCESS door W5.
c. Lubricate packing with petrolatum prior to installation. d. Place packing over and behind tube bead. e. Place second split washer over and behind tube bead. f. Slide coupling nut over washers and engage with boss. g. Tighten coupling nut to specified torque value, using spanner wrench (Table 1). (QA) h. Lockwire coupling. i. Perform FUEL LEAK CHECK this WP. (QA) 39. PRESSURE FUELING ADAPTER VALVE REMOVAL.
Power shall be disconnected from aircraft, static ground cable installed and external power switch tagged before performing fuel system maintenance. Refer to NAVAIR 01-1A-35. f. Remove fueling adapter valve seal cap (1, Figure 4).
Support Equipment Required Nomenclature Container, Safety, Fuel, 5 gal Wrench, Spanner Type Designation/ Part No. CAGE
g. Press valve (8) poppet and drain approximately 3 gallons of residual fuel from manifold into safety fuel container. Before applying power, all electrical access panels shall be closed and personnel alerted that power will be applied. a. Apply power to aircraft (NAVAIR 01-75PAA-2-1, WP 010 00). h. Remove bolts securing valve adapter housing (10) to structure. i. Remove lockwire and disconnect coupling at valve connection to manifold, using spanner wrench (Table 1).
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Figure 4.
Pressure Fueling Adapter Valve Removal and Installation (Sheet 1 of 2)
00400401
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Figure 4.
Pressure Fueling Adapter Valve Removal and Installation (Sheet 2)
00400402
j. Remove valve assembly from aircraft. 40. PRESSURE FUELING ADAPTER VALVE INSTALLATION. Support Equipment Required Nomenclature Wrench, Spanner Type Designation/ Part No. CAGE
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Page 19 h. Perform FUEL LEAK CHECK this WP. (QA) i. Close FUELING STATION ACCESS door W5.
41. NO. 5 FUEL TANK PRESSURE GAUGE REMOVAL.
Materials Required Nomenclature Lockwire Petrolatum Specification/ Part No. MS20995C32 VV-L-236 00). PETROLATUM 2
A conditional inspection for structural damage resulting from overpressurization of fuel tank No. 5 and No. 5A shall be accomplished whenever No. 5 fuel tank pressure gauge indicates in red zone. Refer to NAVAIR 01-75PAA-3-1.
NOTE
No. 5 fuel tank pressure gauge (latching type only) shall be replaced whenever gauge indicates in red zone. a. Defuel aircraft (NAVAIR 01-75PAA-2-1, WP 011
a. Lubricate packings with petrolatum before installation (Figure 4). b. Place packings on fuel manifold line and attach valve housing to manifold with coupling. Do not tighten coupling at this time. c. Position valve on structure and install attaching washers and bolts. d. Tighten manifold coupling to specified torque value, using spanner wrench (Table 1). (QA) e. Lockwire coupling. (QA) f. Install adapter seal cap and chain assembly. g. Remove tag and close circuit breaker.
Power shall be disconnected from aircraft, static ground cable installed and external power switch tagged before performing fuel system maintenance. Refer to NAVAIR 01-1A-35. b. If FUELING STATION ACCESS door W5 is closed, open door. c. Disconnect tube fitting at pressure gauge (Figure 5). Loosen tube fitting at wing rear beam and rotate tube clear of pressure gauge. d. Install plug in tube. e. Support pressure gauge and remove screws and washers. Remove pressure gauge from panel.
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Figure 5.
No. 5 Fuel Tank Pressure Gauge Removal and Installation
004005
f. Remove union from pressure gauge and discard packing. Install plug in open port of gauge. 42. NO. 5 FUEL TANK PRESSURE GAUGE INSTALLATION. Materials Required Nomenclature Petrolatum Specification/ Part No. VV-L-236 PETROLATUM
004 00
Page 21/(22 Blank) b. Remove plugs from gauge and tube (Figure 5). Verify that union and tube are clean. (QA)
c. Lubricate packing with petrolatum and install packing on union. Install union in gauge. d. Install gauge in panel and secure with washers and screws. e. Rotate tube in place on union and connect tube to gauge union. Tighten tube fittings at gauge and bulkhead. f. Service No. 5 fuel tank and check for leaks at gauge and tube (NAVAIR 01-75PAA-2-1, WP 011 00). g. Close FUELING STATION ACCESS door W5.
Power shall be disconnected from aircraft, static ground cable installed and external power switch tagged before performing fuel system maintenance. Refer to NAVAIR 01-1A-35. a. Verify that power is removed from aircraft, static ground cable is installed and external power switch is tagged.
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ORGANIZATIONAL MAINTENANCE WING FUEL TANK COMPONENT MAINTENANCE AIRCRAFT FUEL SYSTEM
Reference Material Aircraft Fuel System Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 004 00 Confined Space (Fuel Tank) Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 008 00 Aircraft Fuel Cells and Tanks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . NAVAIR 01-1A-35 General Information and Servicing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . NAVAIR 01-75PAA-2-1 Line Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 010 00 Fueling System Servicing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 011 00 Airframe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . NAVAIR 01-75PAA-2-2 Powerplant Quick Engine Change Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . NAVAIR 01-75PAA-2-4.5 Emergency Shutdown Controls Rigging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 015 00 Structural Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . NAVAIR 01-75PAA-3-1 Aircraft Refueling for Shore Activities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . NAVAIR 06-5-502 Alphabetical Index Subject Procedures Covered in Other Manuals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Boost Pump Pressure Switch Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Boost Pump Pressure Switch Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Float Vent Valve Installation, P-3C Aircraft BUNOs 161129 and Subsequent and Aircraft Incorporating AFC 392 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Float Vent Valve Removal, P-3C Aircraft BUNOs 161129 and Subsequent and Aircraft Incorporating AFC 392 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fuel Dump Valve and Mast Installation, P-3B and P-3C Aircraft BUNOs 153442 and Subsequent and Aircraft Incorporating AFC 188 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fuel Dump Valve and Mast Removal, P-3B and P-3C Aircraft BUNOs 153442 and Subsequent and Aircraft Incorporating AFC 188 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fuel Tank and Crossfeed Shutoff Valve Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fuel Tank and Crossfeed Shutoff Valve Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Recirculation Line Relief Valve Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Recirculation Line Relief Valve Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Surge Box Flapper Valve Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Surge Box Flapper Valve Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Wing Fuel Tank Boost Pump Dual Check Valve Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Wing Fuel Tank Boost Pump Dual Check Valve Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Wing Fuel Tank Emergency Shutoff Valve Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Wing Fuel Tank Emergency Shutoff Valve Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Wing Fuel Tank Fuel Boost Pump Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Wing Fuel Tank Fuel Boost Pump Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Wing Fuel Tank Fuel Drain Valve Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Wing Fuel Tank Fuel Drain Valve Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Page No. 2 2 23 23 11 9 31 31 24 24 12 11 21 20 30 28 26 25 15 14 35 33
Alphabetical Index (Continued) Subject
005 00
Page 2
Page No. 33 3 2 6 5 8 8
Wing Fuel Tank Fuel Drain Valve Repair and Parts Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . Wing Fuel Tank Fueling and Transfer Valve Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Wing Fuel Tank Fueling and Transfer Valve Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Wing Fuel Tank Pilot Valve Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Wing Fuel Tank Pilot Valve Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Wing Fuel Tank Vent Valve Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Wing Fuel Tank Vent Valve Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Record of Applicable Technical Directives Type/No. AFC 188 Date 2 Mar 70 Title and ECP No. AIRFRAME: Increased Gross Weight and Fuel Dump Capability (ECP 494) 5. Date Inc. 15 Dec 70
Remarks
1. PROCEDURES COVERED IN OTHER MANUALS. 2. The following servicing procedures are covered in NAVAIR 01-75PAA-2-1, WP 011 00: fuel system servicing, fueling precautions, single point pressure fueling, overwing fueling and defueling. 3. Fuel system maintenance safety procedures are covered in NAVAIR 06-5-502 and NAVAIR 01-1A-35.
REMOVAL AND INSTALLATION.
6. WING FUEL TANK FUELING AND TRANSFER VALVE REMOVAL.
Support Equipment Required Type Designation/ Part No. CAGE 925312-1 36659
Nomenclature Tool, Fueling and Transfer Valve Removal and Installation
NOTE
NAVAIR 01-1A-35 shall be used in conjunction with and in support of fuel system maintenance procedures contained in this manual. However, if there is a conflict between NAVAIR 01-1A-35 and the maintenance procedures contained in this manual, NAVAIR 01-1A-35 shall take precedence. 4. Use of the explosive gas detector (part of 72-8001 explosive gas detector set) is covered in WP 008 00 of this manual.
All electrical access panels shall be closed and personnel alerted that power will be applied.
005 00
Page 3 i. body. Remove bonding jumper from the valve
NOTE
In lieu of using valve removal/installation tool, valve may be manually removed by hand. However, care must be exercised not to damage sealing and mating surfaces. a . A p p l y p o w e r t o a i r c r a f t ( N AVA I R 01-75PAA-2-1,WP 010 00). b. On fueling control panel, set FUELING VALVE CONTROL SWITCHES to CLOSED, SYSTEM POWER switch to OFF and tag panel to advise system is not to be operated. c. On FUEL MANAGEMENT panel, set TRANSFER VALVE control switches to CLOSE and tag panel to advise system is not to be operated. d. At main load center on MAIN DC BUS circuit breaker panel, open and tag FUEL INLET VALVE CONT and REFUELING MASTER SW circuit breakers.
j. Remove lockwire from indexing bolt and remove indexing bolt. k. Loosen setscrew securing indexing bolt spacer and pull spacer away from valve body. l. Rotate valve counterclockwise 90 degrees.
m. Position valve removal tool over valve and secure to valve body by tightening wing nut.
Valve body shall not be rotated while removing from valve housing. n. Pull valve body straight out to remove from valve housing. 7. WING FUEL TANK FUELING AND TRANSFER VALVE INSTALLATION.
Personnel and maintenance equipment shall be removed from operational area prior to operating flaps. e. Extend wing flaps to FLAPS DOWN position for access to fueling and transfer valves on wing rear beam (NAVAIR 01-75PAA-2-2).
Support Equipment Required Type Designations/ Part No. CAGE 925312-1 36659
Nomenclature Tool, Fueling and Transfer Valve Removal and Installation
Power shall be disconnected from aircraft, static ground cable installed and external power switch tagged before performing fuel system maintenance. Refer to NAVAIR 01-1A-35. f . R e m o v e p o w e r f r o m a i r c r a f t ( N AVA I R 01-75PAA-2-1, WP 010 00). g. Remove lockwire and disconnect electrical connector at valve (Figure 1). h. Tag, disconnect and cap primary and secondary pilot lines at valve unions.
Materials Required
Nomenclature Lockwire Lockwire Petrolatum
Specification/ Part No. MS20995C20 MS20995C32 VV-L-236
005 00
Page 4
Figure 1.
Wing Fuel Tank Fueling and Transfer Valve Removal and Installation
005001
Change 1 - 1 October 1995
005 00
Page 4A/(4B Blank) a. Verify that switches on fueling control panel are set to OFF or CLOSED and tagged.
Power shall be disconnected from aircraft, static ground cable installed and external power switch tagged before performing fuel system maintenance. Refer to NAVAIR 01-1A-35.
Change 3 - 1 April 2001 b. Verify that switches on FUEL MANAGEMENT panel are set to CLOSE and tagged. c. Install packings and unions at pilot line servoports on valve body.
005 00
Page 5 n. Remove tags from fueling control and FUEL MANAGEMENT panels. o. Perform fuel leak check and operational checks (WP 004 00). (QA) 8. WING FUEL TANK PILOT VALVE REMOVAL.
PETROLATUM
NOTE
This procedure removes the inboard fuel tank pilot valve and is typical of all wing fuel tank pilot valves.
d. Lubricate packing and mating surface with petrolatum and install packing on valve body (Figure 1). e. Align indexing pin on valve body with indexing hole on valve housing and insert valve body straight into valve housing.
Materials Required Specification/ Part No. MIL-C-5040, Type III
Nomenclature Cord, Nylon Valve body shall not be rotated while installing in valve housing. f. Using valve installation tool, insert valve body straight in until bayonet lock bottoms in housing; then rotate valve clockwise 90 degrees to lock. (QA) g. body. h. Remove valve installation tool from valve
Before applying power, electrical access panels shall be closed and personnel alerted that power will be applied. a . A p p l y p o w e r t o a i r c r a f t ( N AVA I R 01-75PAA-2-1, WP 010 00). b. Defuel fuel tank until level of fuel is below valves (NAVAIR 01-75PAA-2-1, WP 011 00).
Install spacer and secure with setscrew.
i. Install bonding jumper between valve housing and valve (Figure 1). j. Install indexing and locking bolt and secure with MS20995C32 lockwire. (QA) j. Install electrical connector on valve and secure connector with MS20995C20 lockwire. (QA) l. Remove caps and attach primary and secondary pilot lines to unions on valve. (QA) m. Remove tags and close circuit breakers.
Before operating control surfaces, personnel and maintenance equipment shall be removed from immediate area. c. Extend wing flaps to FLAPS DOWN (NAVAIR 01-75PAA-2-2).
005 00
Page 6 9 . W I N G F U E L TA N K P I L O T VA LV E INSTALLATION.
Power shall be disconnected from aircraft, static ground cable installed and external power switch tagged before performing fuel system maintenance. Refer to NAVAIR 01-1A-35. d. Re mov e powe r from airc raft (NAVAIR 01-75PAA-2-1, WP 010 00). e. Open wing rear beam junction box and disconnect pilot valve wiring.
NOTE
This procedure installs the inboard fuel tank pilot valve and is typical of all wing fuel tank pilot valves.
Support Equipment Required Type Designation/ Part No. CAGE
Nomenclature Wrench, Torque, 100 to 750 lb-ins
NOTE
In lieu of using valve removal/installation tool, valve may be manually removed by hand. However, care must be exercised not to damage sealing and mating surfaces. f. Attach approximately 10 feet of cord to wiring harness.
Materials Required Specification/ Part No. No. 130AA
Nomenclature Lubriplate
Do not permit contaminants to enter fuel tank. g. Open pilot and float valve access panel in wing upper surfaces (Figure 2).
NOTE
Both pilot and vent valves are installed in this area. The valve most inboard is the pilot valve. h. Disconnect and cap pilot lines from valve and tag for installation. i. Disconnect electrical conduit at valve so wiring can be pulled through conduit. j. Remove bolt from circle clamp at top of valve. k. Lower valve down out of circle clamp and remove valve from fuel tank, pulling electrical wiring through the conduit. l. With valve outside of fuel tank, untie cord from electrical wiring and leave cord extending from fuel tank opening.
Power shall be disconnected from aircraft, static ground installed and external power switch tagged before performing fuel system maintenance. Refer to NAVAIR 01-1A-35. a. Attach valve wiring to exposed cord extending from fuel tank opening. b. Insert pilot valve into fuel tank and position circular mount on top of valve into circle clamp (Figure 2). c. bolts. Secure valve to clamp with washers and
d. Pull pilot valve wiring through electrical conduit at wing rear beam. e. Attach wiring conduit to valve.
005 00
Page 7
005002
Figure 2.
Wing Fuel Tank Vent and Pilot Valve Removal and Installation
005 00
Page 8
LUBRIPLATE
3 Do not permit contaminants to enter fuel tank. d. Open pilot and vent valve access panel in upper wing surface (Figure 2).
f. Lubricate conduit assembly nuts with lubriplate. g. Torque nuts to 400 pound-inches; loosen and torque nuts to 400 40 pound-inches. (QA) h. valve. Remove caps and connect pilot lines to
NOTE
Both vent and pilot valves are installed in this area. The most outboard valve is the vent valve. e. Remove bolts attaching vent line fitting to vent valve. f. Position vent valve inboard of vent line fitting and rotate valve 90 degrees. g. Rotate entire vent valve assembly 180 degrees to inboard and remove valve through access opening. 11. WING FUEL TANK VENT VALVE INSTALLATION.
i. Connect pilot valve wiring at junction box on rear wing beam. j. Install pilot and vent valve access panel on upper wing surface. (QA) k. Perform fuel leak check and operational checks (WP 004 00). (QA) 10. WING FUEL TANK VENT VALVE REMOVAL.
Before applying power, all electrical access panels shall be closed and personnel alerted that power will be applied.
NOTE
This procedure installs the inboard fuel tank vent valve and is typical of all wing fuel tank vent valves.
NOTE
This procedure removes the inboard fuel tank vent valve and is typical of all wing fuel tank vent valves. a . A p p l y p o w e r t o a i r c r a f t ( N AVA I R 01-75PAA-2-1, WP 010 00). b. Defuel fuel tank until level of fuel is below valves (NAVAIR 01-75PAA-2-1, WP 011 00).
Materials Required Specification/ Part No. VV-L-236
Nomenclature Petrolatum
Power shall be disconnected from aircraft, static ground cable installed and external power switch tagged before performing fuel system maintenance. Refer to NAVAIR 01-1A-35. c. Remo ve p ower fro m airc raft (NAVAIR 01-75PAA-2-1, WP 010 00).
a. Install vent valve in fuel tank, aligning valve and line attachment (Figure 2).
005 00
Page 9 c. Rem ov e p ower f ro m ai r craf t (NAVAIR 01-75PAA-2-1, WP 010 00).
PETROLATUM
2 Do not permit contaminants to enter fuel tank. d. Open access panel W106-R or W106-L, as applicable (pilot, vent and float valve access panel).
b. Lubricate packing with petrolatum and install on vent line attachment fitting. c. Move vent valve outboard seating valve and vent line bulkhead fitting and attach fitting to valve. d. Install access panel. (QA)
e. Perform fuel leak check and operational checks (WP 004 00). (QA) 12. FLOAT VENT VALVE REMOVAL, P-3C AIRCRAFT BUNOS 161129 AND SUBSEQUENT AND AIRCRAFT INCORPORATING AFC 392.
NOTE
Both vent and pilot valves are installed under the access panel. The float vent valve is located in the fuel tank aft of these valves. The vent and pilot valve must be moved as an assembly to gain access to the float vent valve. e. Remove nuts, washers and bolts securing vent valve tubing fitting to vent valve (Figure 3). f. Remove bolts, screws and washers securing vent and pilot valves (as an assembly) to fuel tank structure. Do not remove hose connections. g. Move vent and pilot assembly forward and inboard to gain access to float vent valve. h. Cut lockwire securing float vent valve nut to fitting. Loosen nut and remove float vent valve from access opening. i. Remove packing, ring and nut from float vent valve. Discard packing and float vent valve. Retain ring and nut. j. Install protective covers on all fittings.
Before applying power, all electrical access panels shall be closed, static ground cable installed and personnel alerted that power will be applied. a . A p p l y p o w e r t o a i r c r a f t ( N AVA I R 01-75PAA-2-1, WP 010 00). b. Defuel No. 1 or No. 4 fuel tank, as applicable, until level of fuel is below valves (NAVAIR 01-75PAA-2-1, WP 011 00).
005 00
Page 10
005003
Figure 3.
Float Vent Valve Removal and Installation, P-3C Aircraft BUNOs 161129 and Subsequent and Aircraft Incorporating AFC 392
13. FLOAT VENT VALVE INSTALLATION, P-3C AIRCRAFT BUNOS 161129 AND SUBSEQUENT AND AIRCRAFT INCORPORATING AFC 392.
005 00
Page 11 e. Install bolts, washers and nuts to secure vent valve tubing fitting to vent valve. (QA)
f. Install washers on bolts and screws and secure vent and pilot valve assembly to fuel tank structure. (QA)
Nomenclature Wrench, Torque, 100 to 750 lb-ins
Materials Required Specification/ Part No.
COMPOUND, SEALING, POLYSULFIDE
Nomenclature
Compound, Sealing, Polysulfide, MIL-S-8802, Type II for Brush Application Lockwire MS20995C32 Petrolatum VV-L-236
g. Install access panel W106-R or W106-L, as applicable, with seal and sealing compound. (QA)
h.
Perform operational check. (QA)
1 4 . R E C I R C U L AT I O N L I N E R E L I E F VA LV E REMOVAL. Power shall be disconnected from aircraft, static ground cable installed and external power switch tagged before performing fuel system maintenance. Refer to NAVAIR 01-1A-35. a. Remove protective covers from all fittings.
Support Equipment Required Type Designation/ Part No. CAGE AS02 GGG-M-125/1 B, 81348 Type II 72-8001 51906
Nomenclature Mask, Hose Blower Respirator, Air Line
PETROLATUM
Set, Explosive Gas Detector
b. Install nut and ring on new float vent valve. Lubricate packing with petrolatum and install on float vent valve (Figure 2). c. Position float vent valve on fitting, aligning tab on valve with keyway on fitting. Torque nut 120 to 168 pound-inches. Lockwire nut to fitting bracket. (QA) d. Move vent and pilot valve assembly aft and outboard to align assembly with structural attachments and with vent valve tubing fitting.
NOTE
All fuel cell maintenance shall be consist e n t w i t h r e q u i r e m e n t s o f N AVA I R 01-1A-35.
a. Defuel applicable inboard fuel tank (NAVAIR 01-75PAA-2-1, WP 011 00).
b. On fueling control panel, set FUELING VALVE CONTROL SWITCHES to CLOSED, SYSTEM POWER switch to OFF and tag panel to advise system is not to be operated. c. On FUEL MANAGEMENT panel, set all switches to OFF or CLOSE and tag panel to advise system is not to be operated.
005 00
Page 12 1 5 . R E C I R C U L AT I O N L I N E R E L I E F VA LV E INSTALLATION.
Power shall be disconnected from aircraft, static ground cable installed and external power switch tagged before performing fuel system maintenance. Refer to NAVAIR 01-1A-35. d. Re m o v e p o we r fr om a i rc r af t . (N AVA IR 01-75PAA-2-1, WP 010 00). e. Open inboard fuel tank access cover.
Set, Explosive Gas Detector Wrench, Torque, 0 to 150 lb-ins
Nomenclature
Personnel performing maintenance inside fuel tanks shall wear an air-supplied respirator at all times. Fresh air shall be circulated through the fuel tank while personnel are inside. Refer to NAVAIR 01-1A-35. No person shall enter a fuel tank unless certified safe for entry by an aviation gas free engineering technician (AVGFET). Refer to NAVAIR 01-1A-35. f. 00). g. Purge fuel tank (NAVAIR 01-1A-35). Monitor atmosphere in fuel tank (WP 008
Compound, Sealing, Polysulfide, MIL-S-8802, Type II for Brush Application Lockwire MS20995C32 Petrolatum VV-L-236 a. Verify that switches on fueling control panel are set to OFF or CLOSED and tagged. b. Verify that switches on FUEL MANAGEMENT panel are set to OFF or CLOSE and tagged.
h. Remove bolts and nuts securing relief valve in position at outboard end of recirculation line and remove valve from fuel tank (Figure 4).
005 00
Page 13
Figure 4.
Recirculation Line Relief Valve Removal and Installation
005004
005 00
Page 14 16. WING FUEL TANK FUEL BOOST PUMP REMOVAL.
Personnel performing maintenance inside fuel tanks shall wear an air-supplied respirator at all times. Fresh air shall be circulated through the fuel tank while personnel are inside. Refer to NAVAIR 01-1A-35. No person shall enter a fuel tank unless certified safe for entry by an aviation gas free engineering technician (AVGFET). Refer to NAVAIR 01-1A-35. 00). c. Monitor atmosphere in fuel tank (WP 008
Support Equipment Required Type Designation/ Part No. CAGE 80058 36659
Nomenclature
Multimeter AN/USM-311 Tool, Fuel Boost Pump BC65-101 Removal and Installation
Nomenclature PETROLATUM 2 Cord, Nylon
d. Lubricate new packing with petrolatum and install relief valve on recirculation line. e. f. Install and torque nuts to proper value. (QA) Inspect fuel tank for contaminants.
NOTE
All fuel cell maintenance shall be consist e n t w i t h r e q u i r e m e n t s o f N AVA I R 01-1A-35. a. Defuel fuel tank to 3250 pounds or less to bring level of fuel in fuel tank below pump conduit bracket inside of fuel tank access panel (NAVAIR 01-75PAA-2-1, WP 011 00).
g. Close and seal fuel tank access cover with seal and sealing compound. h. Remove tags from fueling control and FUEL MANAGEMENT panels. i. Perform fuel leak check and operational checks (WP 004 00). (QA)
b. Verify that BOOST PUMP control switches on FUEL MANAGEMENT panel are set to OFF and tagged to advise system is not to be operated. c. At main load center on MAIN AC BUS A forward circuit breaker panel, open and tag FUEL BOOSTER PUMP NO. 1 or NO. 3 circuit breaker, or FUEL BOOSTER NO. 2 or NO. 4 circuit breaker on MAIN AC BUS B aft circuit breaker panel, as applicable.
005 00
Page 15
Power shall be disconnected from aircraft, static ground cable installed and external power switch tagged before performing fuel system maintenance. Refer to NAVAIR 01-1A-35. d. Re mov e powe r from airc raft ( NAVAIR 01-75PAA-2-1, WP 010 00).
If fuel boost pump tool is a tight fit on boost pump, tool shall be removed and tool inside dimension enlarged (grinding) to preclude scoring of boost pump motor housing, which would leave metal chips in fuel tank. l. Check fuel boost pump tool for chipping paint and corrosion and proper fit and operation on boost pump. m. Attach fuel boost pump tool ground wire plug to aircraft and lower tool over boost pump and engage boost pump motor housing lugs. n. Turn fuel boost pump tool counterclockwise while maintaining downward force so spring-loaded detent pins on discharge case flange are depressed. o. Continue turning fuel boost pump tool counterclockwise, releasing boost pump from discharge case and withdraw tool with boost pump vertically out of fuel tank.
Do not cut or splice boost pump wiring. e. Tag and disconnect boost pump wires from terminal board in junction box at wing rear beam. f. Attach approximately 10 feet of cord to boost pump wire terminal lugs.
Do not permit contaminants to enter fuel tank through open access panel. g. Remove applicable fuel boost pump panel from upper wing surface (Figure 5). h. Disconnect flex conduit by unscrewing nuts at support bracket and at boost pump cap (Figure 6). i. Pull boost pump wiring out of rigid conduit at support bracket. Untie pull cord and secure to bracket. Pull wiring out of flex conduit. Retain flex conduit for boost pump installation. j. Check fuel boost pump removal and installation tool (tool) for damage and security of components. k. Using multimeter, verify continuity of fuel boost pump removal tool ground wire and plug.
p. Check pump shroud for obvious damage and security. 17. WING FUEL TANK FUEL BOOST PUMP INSTALLATION.
Nomenclature
Multimeter AN/USM-311 Tool, Fuel Boost Pump BC65-101 Removal and Installation Wrench, Torque, 100 to 750 lb-ins
005 00
Page 16
00500501
Figure 5.
Wing Fuel Tank Access Cover Locations (Sheet 1 of 2)
005 00
Page 17
00500502
Figure 5.
Wing Fuel Tank Access Cover Locations (Sheet 2)
005 00
Page 18
005006
Figure 6.
Wing Fuel Tank Fuel Boost Pump Removal and Installation
005 00
Page 19 g. Lower boost pump with fuel boost pump tool into fuel tank and align over discharge case (Figure 6). h. While turning fuel boost pump tool with boost pump clockwise, lower boost pump into discharge case and engage boost pump motor housing lugs with discharge case lugs. (When properly installed the detent locks boost pump to discharge case.) i. Release fuel boost pump tool lock, turn tool counterclockwise to disengage from boost pump motor housing lugs and remove tool vertically from fuel tank. j. Remove fuel boost pump tool ground wire plug from aircraft and set tool aside. k. Attach cord left in conduit to boost pump wire terminal lugs and pull harness through conduit to wing rear beam. l. Attach boost pump harness conduit to bracket in fuel tank adjacent to fuel boost pump access panel. (QA)
Nomenclature
Compound, Sealing, Polysulfide, MIL-S-8802, Type II for Brush Application Lubriplate No. 130AA Sleeving, Anti-chafe, Vinyl, MIL-I-631 Protective, 72 ins
NOTE
Install vinyl anti-chafe protective sleeving, MIL-I-631, on fuel boost pumps received without sleeving. Sleeving should be 72 inches long minimum. Perform continuity check after installation and before applying power. a. Verify that BOOST PUMP control switches on FUEL MANAGEMENT panel are set to OFF and tagged and circuit breaker opened during removal procedure is open and tagged. b. Check fuel boost pump removal and installation tool (tool) for chipping paint, corrosion, component security and damage. c. Using multimeter, verify continuity of fuel boost pump removal tool ground wire and plug.
LUBRIPLATE m. plate.
Lubricate conduit assembly nut with lubri-
n. Torque nut to 400 pound-inches; loosen and torque to 500 100 pound-inches. (QA) If fuel boost pump removal tool is a tight fit on boost pump, tool shall be removed a nd t o o l in s i d e d i m en s i o n e n l a r g e d (grinding) to preclude scoring of boost pump motor housing, which would leave metal chips in fuel tank. d. Check fuel boost pump tool fit on boost pump. e. Attach fuel boost pump tool ground wire plug to aircraft. f. Position fuel boost pump tool over boost pump motor housing and turn tool clockwise, locking boost pump motor housing lugs in tool slot. o. Remove cord from boost pump harness at wing rear beam and connect wire terminal lugs in junction box at rear beam as follows: (QA)
Aircraft wire terminal lugs shall be tight to prevent increased connection resistance which generates excessive heat and melts the terminal board. (1) Before installing boost pump harness wire terminal lugs on junction box terminal board, verify each aircraft wire terminal lug is tightly secured to its terminal
board stud with flatwasher, lockwasher and jamnut. (QA) (2) Install boost pump blue wire terminal lug on terminal board stud A1 and secure with self-locking nut. (QA) (3) Install boost pump yellow wire terminal lug on terminal board stud A2 and secure with self-locking nut. (QA) (4) Install boost pump red wire terminal lug on terminal board stud A3 and secure with self-locking nut. (QA)
005 00
Page 20 t. Perform fuel leak check and operational checks (WP 004 00). (QA) 18. SURGE BOX FLAPPER VALVE REMOVAL.
Nomenclature Mask, Hose Blower Respirator, Air Line Set, Explosive Gas Detector
NOTE
Boost pump black wires are from terminals H1 and H2 of the thermal switch in the boost pump. The black wires are interchangeable. (5) Install boost pump black wire terminal lugs on terminal board studs A4 and A5 and secure with self-locking nuts. (QA) (6) Install boost pump white wire terminal lug on terminal board stud A6 and secure with self-locking nut. (QA) (QA) p. (7) Remove tags from boost pump wires.
NOTE
All fuel cell maintenance shall be consist e n t w i t h r e q u i r e m e n t s o f N AVA I R 01-1A-35. a. Defuel applicable wing fuel tank (NAVAIR 01-75PAA-2-1, WP 011 00). b. On fueling control panel, set FUELING VALVE CONTROL SWITCHES to CLOSED, SYSTEM POWER switch to OFF and tag panel to advise system is not to be operated. c. On FUEL MANAGEMENT panel, set all switches to OFF or CLOSE and tag panel to advise system is not to be operated.
Inspect fuel tank for contaminants.
4 Power shall be disconnected from aircraft, static ground cable installed and external power switch tagged before performing fuel system maintenance. Refer to NAVAIR 01-1A-35. d. Remo ve powe r fr om ai rc raft ( NAVAIR 01-75PAA-2-1, WP 010 00).
q. Install fuel boost pump access panel (Figure 5) with seal and sealing compound (NAVAIR 01-75PAA-3-1). r. Remove tag and close circuit breaker.
s. Remove tags from BOOST PUMP control switches.
e. Open applicable access panel in wing upper surface.
005 00
Page 21
Personnel performing maintenance inside fuel tanks shall wear an air-supplied respirator at all times. Fresh air shall be circulated through the fuel tank while personnel are inside. Refer to NAVAIR 01-1A-35. No person shall enter a fuel tank unless certified safe for entry by an aviation gas free engineering technician (AVGFET). Refer to NAVAIR 01-1A-35. f. g. Purge fuel tank (NAVAIR 01-1A-35). Monitor atmosphere in fuel tank (WP 008
Personnel performing maintenance inside fuel tanks shall wear an air-supplied respirator at all times. Fresh air shall be circulated through the fuel tank while personnel are inside. Refer to NAVAIR 01-1A-35. No person shall enter a fuel tank unless certified safe for entry by an aviation gas free engineering technician (AVGFET). Refer to NAVAIR 01-1A-35. a. Verify that switches on fueling control panel are set to CLOSED or OFF and tagged. b. Verify that switches on FUEL MANAGEMENT panel are set to OFF or CLOSE and tagged. c. Monitor atmosphere in fuel tank (WP 008
00).
h. Remove flapper valve located in surge box inboard forward corner below dual check valve (Figure 7). 19. SURGE INSTALLATION. BOX FLAPPER VA LV E
00).
d. Insert screws with washers through space plate, flapper valve hinge and spacer. Position assembled flapper and spacers over valve port in surge box and install screws (Figure 7). (QA) e. Inspect fuel tank for contaminants. (QA)
Support Equipment Required Type Designation/ Part No. CAGE AS02 GGG-M-125/1B, 81348 Type II 72-8001 51906 COMPOUND, SEALING, POLYSULFIDE Materials Required Specification/ Part No. 4
f. Install fuel tank access panel with seal and sealing compound in wing upper surface. g. Remove tags from fueling control and FUEL MANAGEMENT panels. h. Perform fuel leak check (WP 004 00). (QA)
Nomenclature
Compound, Sealing, Polysulfide, MIL-S-8802, Type II for Brush Application
005 00
Page 22
005007
Figure 7.
Surge Box Flapper Valve Removal and Installation
20. BOOST PUMP PRESSURE SWITCH REMOVAL. h.
005 00
Page 23 Remove pressure switch from pressure line.
21. BOOST PUMP PRESSURE SWITCH INSTALLATION.
Before applying power, electrical access panels shall be closed and personnel alerted that power will be applied. a . A p p l y p o w e r t o a i r c r a f t ( N AVA I R 01-75PAA-2-1, WP 010 00). Nomenclature Lockwire Petrolatum
Personnel and maintenance equipment shall be removed from operational area prior to operating flaps. b. Set wing flaps to FLAPS DOWN for access to pressure switch (NAVAIR 01-75PAA-2-2). c. Verify that BOOST PUMP control switches on FUEL MANAGEMENT panel are set to OFF and tagged to advise system is not to be operated.
Power shall be disconnected from aircraft, static ground cable installed and external power switch tagged before performing fuel system maintenance. Refer to NAVAIR 01-1A-35. a. Verify that BOOST PUMP control switches on FUEL MANAGEMENT panel are set to OFF and tagged.
Power shall be disconnected from aircraft, static ground cable installed and external power switch tagged before performing fuel system maintenance. Refer to NAVAIR 01-1A-35. d. Re mov e powe r from airc raft ( NAVAIR 01-75PAA-2-1, WP 010 00). e. f. Remove electrical connector from switch. Remove drain tube from bottom of switch.
PETROLATUM
b. Lubricate packing with petrolatum and install on pressure switch fitting and attach pressure sensing line. (QA) c. Lubricate new packing with petrolatum and install on switch drain line union. Attach drain line to union. (QA) d. Install electrical connector on pressure switch and lockwire. (QA) e. Install rear beam structural brace on No. 2 and No. 3 fuel tanks. (QA) f. Remove tags from control switches.
NOTE
For removal of No. 2 and No. 3 fuel tank switches, it is necessary to remove a structural brace which interferes with switch removal. g. Remove screws, nuts and washers securing brace and swing brace to the side for access to switch.
g. Perform fuel leak check and operational checks (WP 004 00). (QA)
Change 1 - 1 October 1995 22. FUEL TANK AND CROSSFEED SHUTOFF VALVE REMOVAL.
005 00
Page 24 23. FUEL TANK AND CROSSFEED SHUTOFF VALVE INSTALLATION.
NOTE
All fuel ceil maintenance shall be consist e n t w i t h r e q u i r e m e n t s o f N AVA I R 01-1A-35. Nomenclature a. Verify that MAIN TANK VALVE and CROSSFEED VALVE switches on FUEL MANAGEMENT panel are set to CLOSE and panel tagged to advise system is not to be operated. b. At forward load center on MONITORABLE ESSENTIAL AC BUS circuit breaker panel, open and tag FUEL TANK SHUTOFF VALVE CONT and CROSSFEED VALVE ACTUATORS circuit breakers for applicable fuel tank. c. Open wing leading edge panels (NAVAIR 01-75PAA-2-2). Power shall be disconnected from aircraft, static ground cable installed and external power switch tagged before performing fuel system maintenance. Refer to NAVAIR 01-1A-35. a. Verify MAIN TANK VALVE and CROSSFEED VALVE control switches on FUEL MANAGEMENT panel are set to CLOSE and tagged. b. Verify circuit breakers opened during removal procedure are open and tagged. Lockwire Lockwire Petrolatum Materials Required Specification/ Part No. MS20995C20 MS20995C32 VV-L-236
Power shall be disconnected from aircraft, static ground cable installed and external power switch tagged before performing fuel system maintenance. Refer to NAVAIR 01-1A-35. d. Remove valve electrical connector.
e. Remove valve positioning locking screw (Figure 8). f. Pull indexing pin and rotate valve body counterclockwise 90 degrees. g. Pull valve body out approximately 3/8 inch, then rotate an additional 90 degrees counterclockwise and then pull straight out removing valve from housing. Do not rotate valve body during removal.
PETROLATUM
c. Lubricate packing and mating surface of valve with petrolatum. d. Align valve body indexing pin with indexing hole in housing and insert valve body as far as it will go into housing (Figure 8). e. Rotate valve counterclockwise until lugs on valve line up with slots in housing.
005 00
Page 25
005008
Figure 8.
Fuel Tank and Crossfeed Shutoff Valve Removal and Installation
l. Close wing leading edge access panels (NAVAIR 01-75PAA-2-2). If valve does not easily push in, valve shall be removed and inner valve housing sleeve checked to ensure that it has not rotated from friction of new packings. f. Firmly press valve straight into housing, then rotate valve clockwise until indexing pin engages indexing hole in housing. (QA) g. Install positioning locking screw and secure with MS20995C32 lockwire. (QA) h. Install electrical connector plug on valve solenoid and secure with MS20995C20 lockwire. (QA) i. Remove tags from FUEL MANAGEMENT panel. j. Remove tags and close circuit breakers. k. Perform fuel leak check and operational checks (WP 004 00). (QA) Nomenclature Type Designation/ Part No. CAGE 36659 Support Equipment Required
24. WING FUEL TANK EMERGENCY SHUTOFF VALVE REMOVAL.
Tool, Valve Body Removal 823739-1 and Installation
NOTE
All fuel cell maintenance shall be consist e n t w i t h r e q u i r e m e n t o f N AVA I R 01-1A-35. a. Pull and tag applicable engine emergency shutdown handle. b . O p e n w i n g l e a d i n g e d g e ( N AVA I R 01-75PAA-2-2).
005 00
Page 26 apply impact action on tool, pulling valve body straight out of housing approximately 3/8 inch. h. Rotate valve an additional 90 degrees counterclockwise and then remove from housing by pulling straight out. 25. WING FUEL TANK EMERGENCY SHUTOFF VALVE INSTALLATION
Support Equipment Required Type Designation/ Part No. CAGE 36659
Power shall be disconnected from aircraft, static ground cable installed and external power switch tagged before performing fuel system maintenance. Refer to NAVAIR 01-1A-35. c. Disconnect actuating rod at valve actuating arm (Figure 9). d. Verify valve is set to CLOSED by attempting to rotate valve actuating arm counterclockwise to full closed position. e. Remove valve positioning locking screw.
Nomenclature
Tool, Valve Body Removal 833739-1 and Installation
Do not allow valve body to rotate clockwise during removal. f. Pull indexing pin and rotate valve body approximately 90 degrees counterclockwise, or until lugs on valve match slots in housing.
Use care to prevent damage to control cables and heat barrier when removing valve body. g. Insert valve body removal and installation tool (tool) under actuating arm at valve shaft and
PETROLATUM
a. Lubricate packing and mating surface of valve with petrolatum. (QA) b. Insert valve body into housing with index pin 180 degrees from index hole on housing (Figure 9).
005 00
Page 27
005009
Figure 9.
Wing Fuel Tank Emergency Shutoff Valve Removal and Installation
c. Rotate valve clockwise using valve body removal and installation tool until lugs on valve line up with slots in housing. ing. d. Firmly press valve body straight into hous-
005 00
Page 28
e. While maintaining pressure, rotate valve body clockwise until index pin engages the indexing hole in housing. f. Install positioning locking screw and secure with lockwire. (QA) g. Remove tag and reset emergency shutdown handle. h. Verify valve is properly rigged (NAVAIR 01-75PAA-2-4.5, WP 015 00). (QA) i. Perform fuel leak check and operational checks (WP 004 00). (QA) j . C l o s e w i n g l e a d i n g e d g e ( N AVA I R 01-75PAA-2-2). 26. WING FUEL TANK BOOST PUMP DUAL CHECK VALVE REMOVAL.
Do not permit contaminants to enter fuel tank through open access panel. c. Open access panel from upper wing surface. (Figure 5).
Personnel performing maintenance inside fuel tanks shall wear an air-supplied respirator at all times. Fresh air shall be circulated through the fuel tank while personnel are inside. Refer to NAVAIR 01-1A-35. No person shall enter a fuel tank unless certified safe for entry by an aviation gas free engineering technician (AVGFET). Refer to NAVAIR 01-1A-35. d. 00). e. Purge fuel tank (NAVAIR 01-1A-35). Monitor atmosphere in fuel tank (WP 008
NOTE
All fuel cell maintenance shall be consist e n t w i t h r e q u i r e m e n t s o f N AVA I R 01-1A-35. a . D e f u e l a p p l i c a b l e f u e l t a n k ( N AVA I R 01-75PAA-2-1, WP 011 00). b. Verify that BOOST PUMP control switches on FUEL MANAGEMENT panel are set to OFF and tagged to advise fuel system is not to be operated.
f. Remove engine feedline connected to dual check valve. Disconnect pump discharge line from dual check valve and pump (Figure 10).
Do not leave old packing in fuel tank when disconnecting screen bypass line from check valve. g. Remove bolts securing screen bypass line to check valve.
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Page 29
Figure 10.
Wing Fuel Boost Pump Dual Check Valve Removal and Installation
005010
h. Remove bulkhead fitting locknuts securing valve to surge box wall and remove dual check valve. 27. WING FUEL TANK BOOST PUMP DUAL CHECK VALVE INSTALLATION.
005 00
Page 30 personnel are inside. Refer to NAVAIR 01-1A-35. No person shall enter a fuel tank unless certified safe for entry by an aviation gas free engineering technician (AVGFET). Refer to NAVAIR 01-1A-35. b. Monitor atmosphere in fuel tank (WP 008
Support Equipment Required 00). Nomenclature Mask, Hose Blower Respirator, Air Line Set, Explosive Gas Detector Type Designation/ Part No. CAGE AS02 GGG-M-125/1B, 81348 Type II 72-8001 51906
c. Install dual check valve to surge box forward wall opening with bulkhead fitting locknuts (Figure 10). d. Install engine feed line to valve and install pump discharge line to valve and pump. (QA)
Materials Required PETROLATUM Nomenclature Specification/ Part No. 2
Compound, Sealing, Polysulfide, MIL-S-8802, Type II for Brush Application Petrolatum VV-L-236
e. Lubricate packing with petrolatum and install at screen bypass line to check valve fitting and install bolts. f. Verify all connections are properly installed and torqued. (QA) g. Inspect fuel tank interior for contaminants.
Power shall be disconnected from aircraft, static ground cable installed and external power switch tagged before performing fuel system maintenance. Refer to NAVAIR 01-1A-35. a. Verify BOOST PUMP switches on FUEL MANAGEMENT panel are set to OFF and tagged. COMPOUND, SEALING, POLYSULFIDE 4
h. Install access panel with seal and sealing compound. i. Remove tags from FUEL MANAGEMENT panel. j. Perform fuel leak check and operational checks (WP 004 00). (QA)
Personnel performing maintenance inside fuel tanks shall wear an air-supplied respirator at all times. Fresh air shall be circulated through the fuel tank while
28. FUEL DUMP VALVE AND MAST REMOVAL, P-3B AND P-3C AIRCRAFT BUNOs 153442 AND SUBSEQUENT AND AIRCRAFT INCORPORATING AFC 188. i.
005 00
Page 31 Disconnect electrical connector.
j. Remove dump valve attachment bolts (12), bonding jumper and dump valve (2). 2 9 . F U E L D U M P VA LV E A N D M A S T I N S TA L L AT I O N , P - 3 B A N D P - 3 C A I R C R A F T BUNOs 153442 AND SUBSEQUENT AND AIRCRAFT INCORPORATING AFC 188.
NOTE
All fuel cell maintenance shall be consist e n t w i t h r e q u i r e m e n t s o f N AVA I R 01-1A-35. a. Defuel No. 5 fuel tank to 6500 pounds or less to bring fuel level in fuel tank below dump valve (NAVAIR 01-75PAA-2-1, WP 011 00). b. At main load center on MAIN AC BUS A aft circuit breaker panel, open and tag FUEL DUMP PUMP circuit breaker and FUEL DUMP CONT and FUEL DUMP VALVE circuit breakers on MAIN DC BUS circuit breaker panel. c. At forward load center on EXTENSION MAIN DC BUS circuit breaker panel, open and tag FUEL TRANSFER PUMP CONT FWD and AFT circuit breakers.
Materials Required Specification/ Part No. MS20995C20 MS20995C32 VV-L-236
Power shall be disconnected from aircraft, static ground cable installed and external power switch tagged before performing fuel system maintenance. Refer to NAVAIR 01-1A-35. d. Re mov e powe r from airc raft ( NAVAIR 01-75PAA-2-1, WP 010 00). e. Remove screws (6, 9, Figure 11) attaching fuel dump mast (7) to wing. f. Loosen screw at clamp (11) securing sleeve (10) and dump mast (7). g. Remove lockwire and loosen coupling nut (4) and slide dump mast (7) aft. h. Remove dump tube (3) attaching nuts from dump valve (2) and remove tube.
Power shall be disconnected from aircraft, static ground cable installed and external power switch tagged before performing fuel system maintenance. Refer to NAVAIR 01-1A-35. a. Verify circuit breakers opened during removal procedure are open and tagged. b. Install dump valve (2, Figure 11) and dump tube (3) with attachment bolts (12) to rear beam fitting (13). Torque bolts. (QA) c. Attach bonding jumper.
d. Install and secure electrical connector with MS20995C20 lockwire. (QA)
PETROLATUM
005 00
Page 32
Figure 11.
Fuel System Dump Valve and Mast Removal and Installation, Aircraft BUNOs 153442 and Subsequent and Aircraft Incorporating AFC 188
005011
e. Lubricate coupling packing (4) and mating surfaces with petrolatum. f. Install coupling packing (4) and slide dump mast (7) forward to mate with dump tube (3). g. Attach coupling nut (4), but do not tighten at this time. h. Position dump mast (7) at top of left wing (5) and install screws (6, 9). (QA) i. Position sleeve (10) and clamp (11) on dump mast (7) and tighten clamp screw. j. Torque coupling nut (4) and secure with MS20995C32 lockwire. (QA) k. Remove tags and close circuit breakers.
005 00
Page 33
Power shall be disconnected from aircraft, static ground cable installed and external power switch tagged before performing fuel system maintenance. Refer to NAVAIR 01-1A-35. c. Rem ov e p ower f ro m ai r craf t (NAVAIR 01-75PAA-2-1, WP 010 00). d. Test drain valve operating action by manually pressing poppet. (Action should be smooth and force required to open valve is 103.0 pounds.) (QA) e. Remove screws (1, Figure 12) securing valve retention cap (2) and remove cap.
l. Perform functional check (aircraft BUNOs 153442 and subsequent and aircraft incorporating AFC 188) (WP 004 00). m. Perform fuel leak check (WP 004 00). (QA)
30. WING FUEL TANK FUEL DRAIN VALVE REMOVAL. Support Equipment Required Nomenclature Gauge, Force, 0 to 25 lb Type Designation/ Part No. CAGE
Exercise caution when removing retainer. Poppet is spring-loaded against retainer. f. Remove screws (4) securing retainer(s) (5) and remove valve by pulling straight down. 31. WING FUEL TANK FUEL DRAIN VALVE REPAIR AND PARTS REPLACEMENT.
Support Equipment Required
NOTE
All fuel cell maintenance shall be consistent with requirement of NAVAIR 01-1A-35. a . D e f u e l a p p l i c a b l e f u e l t a n k ( N AVA I R 01-75PAA-2-1, WP 011 00). b. Tag FUEL MANAGEMENT panel to advise fuel system is not to be operated. Nomenclature
Type Designation/ Part No. CAGE 81349 81348 81348
Coveralls MIL-C-14610 Gloves, Rubber, Industrial ZZ-G-381 Goggles, Industrial GG-G-531 and Spectacles
005 00
Page 34
Figure 12.
Wing Fuel Tank Fuel Drain Valve Removal and Installation
005012
NOTE
Materials Required Specification/ Part No. CCC-C-46, Type 1, Class 4 P-D-680,Type III or II (Type III preferred) 5812-8
005 00
Page 35
Nomenclature Brush, Bristle Cloth, Cleaning Solvent, Dry Cleaning Spring a.
Replace spring (10) if force required to open poppet (9) is not within 10 3.0 pounds. Refer to WING FUEL TANK FUEL DRAIN VALVE REMOVAL and/or WING FUEL TANK FUEL DRAIN VALVE INSTALLATION this WP for force testing of poppet valve.
(2) Replace defective parts unless minor repair restores serviceability.
Clean drain valve components as follows: (3) Replace any defective part which affects sealing or operation action.
SOLVENT, DRY CLEANING, TYPE III
5 d. Perform WING FUEL TANK FUEL DRAIN VALVE INSTALLATION this WP.
32. WING FUEL TANK FUEL DRAIN VALVE INSTALLATION. SOLVENT, DRY CLEANING, TYPE II 6
(1) Clean all metal parts in dry cleaning solvent. (Use of brush helps cleaning of poppet (9, Figure 12), drain valve body (12) and valve seat areas.) (2) Thoroughly dry all parts with clean cleaning cloth. b. Inspect drain valve components for defects.
Nomenclature Gauge, Force, 0 to 25 lb
(1) Inspect drain valve body (12) and poppet (9) seat for areas of concentrated wear and scoring. (QA) (2) Inspect retainer (2) seats for damage. Materials Required Specification/ Part No. VV-L-236
(QA)
(3) Inspect helicoils (11) and screws (1, 4) for damage to threads. (QA) c. Repair and/or replace parts as follows: (1) Replace all packings (3, 6, 7, 8).
005 00
Page 36 c. Insert spring (10), poppet (9) with packings (6, 7, 8) installed and retainer (5) into drain valve body (12) and secure with screws (4). (QA)
Power must be disconnected from aircraft, static ground cable installed and external power switch tagged before performing fuel system maintenance. Refer to NAVAIR 01-1A-35. a . Ve r i f y F U E L M A N A G E M E N T p a n e l i s tagged.
d.
Torque screws (4). (QA)
e. Position packing (3) around seat on retainer cap (2) and align with screw (1) holes on retainer (5) and drain valve body (12). (QA) f. Install screws (1) and torque. (QA)
PETROLATUM
b. Lubricate poppet (9, Figure 12) and packings (6, 7, 8) with petrolatum prior to assembly.
g. Test drain valve operating action by manually pressing poppet (9). (Action should be smooth and force required to open valve is 10 3.0 pounds.) (QA) h. Remove tags from FUEL MANAGEMENT panel.
Packing must be seated properly during installation.
i. Perform fuel leak check and operational checks (WP 004 00). (QA)
Change 1 - 1 October 1995 ORGANIZATIONAL MAINTENANCE CENTER SECTION FUEL TANK COMPONENT MAINTENANCE AIRCRAFT FUEL SYSTEM
006 00
Page 1
Reference Material Aircraft Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 004 00 Confined Space (Fuel Tank) Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 008 00 Aircraft Fuel Cells and Tanks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . NAVAIR 01-1A-35 General Information and Servicing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . NAVAIR 01-75PAA-2-1 Line Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 010 00 Fuel System Servicing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 011 00 Connector and Wire Repair Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . NAVAIR 01-75PAA-2-15 Electrical Connector Part Numbers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 007 00 Aircraft Refueling for Shore Activities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . NAVAIR 06-5-502 Alphabetical Index Subject Procedures Covered in Other Manuals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Center Section Fuel Tank Drain Valve Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Center Section Fuel Tank Drain Valve Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Center Section Fuel Tank Drain Valve Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Center Section Fuel Tank Pilot Valve Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Center Section Fuel Tank Pilot Valve Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Center Section Fuel Tank Pressure Fueling and Transfer Valve Installation . . . . . . . . . . . . . . . . . . . Center Section Fuel Tank Pressure Fueling and Transfer Valve Removal . . . . . . . . . . . . . . . . . . . . . Center Section Fuel Tank Sight Gauge Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Center Section Fuel Tank Sight Gauge Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Center Section Fuel Tank Vent Valve Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Center Section Fuel Tank Vent Valve Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Crossfeed Manifold Pressure Transmitter Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Crossfeed Manifold Pressure Transmitter Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Crossfeed Thermal Relief Valve Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Crossfeed Thermal Relief Valve Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Dump Pump Installation, P-3B Aircraft BUNOs 153442 and Subsequent and P-3A and P-3B Aircraft Incorporating AFC 188 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Dump Pump Removal, P-3B Aircraft BUNOs 153442 and Subsequent and P-3A and P-3B Aircraft Incorporating AFC 188 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Page No. 2 2 11 8 10 17 14 6 2 12 11 19 18 7 7 26 24 23 20
Record of Applicable Technical Directives Type/No. AFC 188 Date 2 Mar 70 Title and ECP No. AIRFRAME: Increased Gross Weight and Fuel Dump Capability (ECP 494) Date Inc. 15 Dec 70
006 00
Page 2
Remarks
1. PROCEDURES COVERED IN OTHER MANUALS. 2. Fuel system servicing and fueling precautions are covered in NAVAIR 01-75PAA-2-1. Fuel system maintenance safety procedures are covered in NAVAIR 06-5-502 and NAVAIR 01-1A-35.
c. Open center section compartment access panel. d. Remo ve powe r fr om ai rc raft ( NAVAIR 01-75PAA-2-1, WP 010 00).
NOTE
NAVAIR 01-1A-35 shall be used in conjunction with and in support of fuel system maintenance procedures contained in this manual. However, if there is a conflict between NAVAIR 01-1A-35 and the maintenance procedures contained in this manual, NAVAIR 01-1A-35 shall take precedence. 3. REMOVAL AND INSTALLATION. Power shall be disconnected from aircraft, static ground cable installed and external power switch tagged before performing fuel system maintenance. Refer to NAVAIR 01-1A-35. e. Disconnect electrical connector from pressure fueling and transfer valve (17, Figure 1). f. Remove two bonding jumpers from external fuel tank refueling piping (Figure 2). g. Disconnect external fuel tank refueling pipes by removing bolts, swivel fittings and gaskets. Discard gaskets and cap pipes. Tag lines and remove from compartment. h. Remove lockwire from valve body position lock bolt and remove bolt.
4. CENTER SECTION FUEL TANK PRESSURE FUELING AND TRANSFER VALVE REMOVAL.
NOTE
All fuel cell maintenance shall be consistent with r equirements of NAVAIR 01-1A-35. a . V e r i f y F U E L I N G VA LV E C O N T R O L SWITCHES on fueling control panel are set to CLOSED and tagged and TRANSFER VALVE control switches on FUEL MANAGEMENT panel are set to CLOSE and tagged to advise fuel system is not to be operated. b. At main load center on MAIN DC BUS circuit breaker panel, open and tag all FUEL INLET VALVE CONT and REFUELING MASTER SW circuit breakers.
Do not rotate valve body while removing from housing or seals may be damaged. i. Rotate valve body counterclockwise 90 degrees, then slowly pull valve body from housing.
006 00
Page 3/(4 Blank)
Figure 1.
Center Section Fuel Tank Component Removal and Installation
006001
006 00
Page 5
006002
Figure 2.
Center Section Fuel Tank Pressure Fueling and Transfer Valve Removal and Installation
5. CENTER SECTION FUEL TANK PRESSURE FUELING AND TRANSFER VALVE INSTALLATION. Support Equipment Required Nomenclature Type Designation/ Part No. CAGE 81348 81348
006 00
Page 6 d. Align indexing pin on valve body with indexing hole in valve housing and insert valve body straight into valve housing (Figure 2).
e. Insert valve body until bayonet lock bottoms in housing, then rotate valve clockwise 90 degrees to lock. (QA)
Gloves, Rubber, Industrial ZZ-G-381 Goggles, Industrial GG-G-531 and Spectacles
f. Install indexing and locking bolt and secure with MS20995C32 lockwire. (QA)
g. Remove caps and connect external fuel tank refueling pipes to valve and fuel tank wall fittings with packings and bolts. (QA)
Compound, Sealing, Polysulfide MIL-S-8784, Type II Lockwire MS20995C20 Lockwire MS20995C32 Petrolatum VV-L-236 a . V e r i f y F U E L I N G VA LV E C O N T R O L SWITCHES are set to CLOSED and tagged and TRANSFER VALVE control switches are set to CLOSE and tagged. COMPOUND, SEALING, POLYSULFIDE 7
h. Install bonding jumpers from clamps on piping to valve. Bond faying surfaces and seal with sealing compound. (QA)
PETROLATUM b. Lubricate packings with petrolatum.
2 i. Install electrical connector to valve solenoid and secure with MS20995C20 lockwire. (QA)
j. Remove tags from fueling control panel and FUEL MANAGEMENT panel. Power shall be disconnected from aircraft, static ground cable installed and external power switch tagged before performing fuel system maintenance. Refer to NAVAIR 01-1A-35. c. Verify power is removed from aircraft (NAVAIR 01-75PAA-2-1, WP 010 00).
k. Perform fuel leak check and functional check (WP 004 00). (QA)
l. Close center section compartment access panel.
6. CROSSFEED MANIFOLD TRANSMITTER REMOVAL. PRESSURE
006 00
Page 7 e. Disconnect and drain residual fuel from pressure tube from crossfeed fuel sensing transmitter fitting (15) and drain tube (16) at transmitter unions (24) into safety fuel container. Cap and tag tubes for installation. f. At inboard end of transmitter (22), remove screw (25), washer (26) and clamp (27). g. At outboard end of transmitter (22), remove screws (20) and washers (19) securing transmitter to mount bracket (21). h. Remove transmitter (22).
Nomenclature Container, Safety, Fuel, 5 gal
NOTE
All fuel cell maintenance shall be consistent with requirements of NAVAIR 01-1A-35. a . Ve r i f y C R O S S F E E D VA LV E c o n t r o l switches on FUEL MANAGEMENT panel are set to CLOSE and tagged to advise system is not to be operated. b. Open center section compartment access panel and adjacent access panel.
i. Remove unions (24) and packings (23) from transmitter (22). Retain unions for installation and discard packings. 7. CROSSFEED MANIFOLD TRANSMITTER INSTALLATION. PRESSURE
Nomenclature Lockwire Petrolatum Power shall be disconnected from aircraft, static ground cable installed and external power switch tagged before performing fuel system maintenance. Refer to NAVAIR 01-1A-35. c. Remo ve p ower fro m airc raft ( NAVAIR 01-75PAA-2-1, WP 010 00). d. Remove electrical connector from crossfeed manifold pressure transmitter (transmitter) (22, Figure 1).
Power shall be disconnected from aircraft, static ground cable installed and external power switch tagged before performing fuel system maintenance. Refer to NAVAIR 01-1A-35. a. Verify power is removed from aircraft (NAVAIR 01-75PAA-2-1, WP 010 00). b . Ve r i f y C R O S S F E E D VA LV E c o n t r o l switches are set to CLOSE and tagged. c. Position crossfeed manifold pressure transmitter (transmitter) (22, Figure 1) in mount bracket (21) and secure with washers (19) and screws (20).
d. Install clamp (27) on inboard end of transmitter (22) and secure clamp with screw (25) and washer (26).
006 00
Page 8
NOTE
All fuel cell maintenance shall be consistent with requirements of NAVAIR 01-1A-35. a. Defuel No. 5 fuel tank (bladder cell and center section) (NAVAIR 01-75PAA-2-1, WP 011 00). b. Tag FUEL MANAGEMENT panel and fueling control panel to advise fuel system is not to be operated.
NOTE
The pressure line port on the transmitter is marked P and the drain line port is marked V.
PETROLATUM
e. Lubricate packings (23) with petrolatum and install on unions (24). Install unions at pressure and drain ports. (QA) f. Attach pressure tube from crossfeed fuel sensing transmitter fitting (15) and drain tube (16) to unions (24) on transmitter (22). (QA) g. Install electrical connector on transmitter (22) and lockwire. (QA) h. Remove tags from FUEL MANAGEMENT panel. i. Perform fuel leak check and functional check (WP 004 00). (QA) j. Close center section compartment access panel. 8. CENTER SECTION FUEL TANK DRAIN VALVE REMOVAL. Power shall be disconnected from aircraft, static ground cable installed and external power switch tagged before performing fuel system maintenance. Refer to NAVAIR 01-1A-35. c. Rem ov e p ower f ro m ai rc r aft ( NAVAIR 01-75PAA-2-1, WP 010 00).
Support Equipment Required Type Designation/ Part No. CAGE DPP-30 11701
d. Drain residual fuel into safety fuel container (NAVAIR 01-75PAA-2-1, WP 011 00). e. Remove screws (3, Figure 3) securing drain valve (2). f. g. Remove drain valve (2). Remove and discard packing (1).
Nomenclature Container, Safety, Fuel, 5 gal Gauge, Force, 0 to 25 lb-ins
006 00
Page 9
006003
Figure 3.
Center Section Fuel Tank Drain Valve Removal and Installation
9. CENTER SECTION FUEL TANK DRAIN VALVE REPAIR. d. lows:
006 00
Page 10 Clean drain valve (2) components as fol-
Support Equipment Required Type Designation/ Part No. CAGE MIL-C-14610 ZZ-G-381 GG-G-531 GG-M-125/6 81349 81348 81348 81348 SOLVENT, DRY CLEANING, TYPE II 6 SOLVENT, DRY CLEANING, TYPE III 5
Nomenclature Coveralls Gloves, Rubber, Industrial Goggles, Industrial and Spectacles Respirator, Cartridge Organic Vapor
Materials Required Specification/ Part No. CCC-C-46, Type 1, Class 4 MS20995C32 VV-L-236 P-D-680, Type III or II (Type III preferred)
(1) Clean all metal parts in dry cleaning solvent. Use of bristle brush helps cleaning of poppet, body and valve seat areas. (2) Thoroughly dry all parts with clean cleaning cloth. e. Inspect drain valve (2) components for defects. (1) Inspect drain valve body (14) and poppet (7) seat for areas of concentrated wear and scoring. (QA) (2) Inspect retainer (5, 11) seats for damage. (QA) (3) Inspect helicoils and screws (3, 12) for damage to threads. (QA) f. Repair and/or replace parts as follows: (1) Replace all packings.
Nomenclature Brush, Bristle Cloth, Cleaning Lockwire Petrolatum Solvent, Dry Cleaning
The valve spring retainer is compressing a spring so care shall be exercised when removing it to prevent spring retainer and spring from exiting drain valve body at high velocity. a. Remove lockwire (4, Figure 3) and carefully remove spring retainer (5) from drain valve body (14). b. Remove spring (6) and poppet (7). Remove and discard packings (8, 9). c. Remove screws (12) and seal retainer (11) from drain valve body (14). Remove and discard packing (10).
NOTE
Replace spring (6) if force required to open poppet (7) is not within 10 3.0 pounds. Refer to force testing of poppet valve in step k of this procedure. (2) Replace defective parts unless minor repair restores serviceability.
(3) Replace any defective part which affects sealing or operation action. PETROLATUM PETROLATUM 2 c. tum.
006 00
Page 11
Lubricate packing (1, Figure 3) with petrola-
g. Lubricate all packings and poppet (7) with petrolatum. h. Install packing (10) and seal retainer (11) on drain valve body (14) and secure with screws (12). (7). i. Install packing (8) and packing (9) on poppet
The packing shall be seated properly during installation. d. Install packing (1) on drain valve body (14) of drain valve (2). Verify packing is seated properly. (QA) e. Install drain valve (2) in fuel tank and secure with screws (3). f. Test drain valve operating action by pressing poppet. Action should be smooth and force required to open valve is 103.0 pounds. (QA) g. Remove tags from FUEL MANAGEMENT panel. h. Perform fuel leak check (WP 004 00). (QA)
j. Install poppet spring (6) and spring retainer (5) in drain valve body (14). Secure spring retainer with lockwire (4). (QA) k. Test drain valve operating action by pressing poppet. Action should be smooth and force required to open valve is 103.0 pounds. (QA) 10. CENTER SECTION FUEL TANK DRAIN VALVE INSTALLATION.
11. CENTER SECTION FUEL TANK SIGHT GAUGE REMOVAL.
Nomenclature Power shall be disconnected from aircraft, static ground cable installed and external power switch tagged before performing fuel system maintenance. Refer to NAVAIR 01-1A-35. a. Verify power is removed from aircraft (NAVAIR 01-75PAA-2-1, WP 010 00). b . Ve r i f y F U E L M A N A G E M E N T p a n e l i s tagged to advise fuel system is not to be operated. Container, Safety, Fuel, 5 gal
NOTE
All fuel cell maintenance shall be consistent with requirements of NAVAIR 01-1A-35. a. Defuel No. 5 fuel tank (bladder cell and center section) (NAVAIR 01-75PAA-2-1, WP 011 00).
b. Verify switches on FUEL MANAGEMENT panel are set to CLOSE or OFF and tagged and s wi t c he s o n fu e l i n g c o n tr ol p a n e l a re s e t t o CLOSED or OFF and tagged to advise fuel system is not to be operated. c. Remo ve p ower fro m airc raft (NAVAIR 01-75AAA-2-1, WP 010 00). d. Remove ground plane access door (Figure
006 00
Page 12 s wi t c h es o n fu e l i n g c o n tr o l pa n e l a r e s e t to CLOSED or OFF and tagged to advise fuel system is not to be operated. b. Verify power is removed from aircraft (NAVAIR 01-75PAA-2-1, WP 010 00).
1).
e. Release and completely extend calibrated slip tube (Figure 4).
Do not allow slip tube to push in ahead of tube base as damage to the housing flapper valve results. c. Push tube base fully to top of calibrated tube (Figure 4).
Power shall be disconnected from aircraft, static ground cable installed and external power switch tagged before performing fuel system maintenance. Refer to NAVAIR 01-1A-35. f. Remove screws and washers from tube base.
PETROLATUM
d. Lubricate packing with petrolatum and install on tube base. e. Insert tube base into housing.
The slip tube shall be fully extended before removing from housing. g. Pull slip tube and tube base straight down from housing, taking care not to damage housing seal. 12. CENTER SECTION FUEL TANK SIG HT GAUGE INSTALLATION.
f. On P-3A, P-3B and P-3C aircraft BUNOs 148883 through 159513, secure base to housing with screws and washers. g. On P-3C aircraft BUNOs 159514 and subsequent, install AN960D416 washer under screw head, then NAS1523-4F washer. h. Push calibrated slip tube into fuel tank until tube is seated in support at top of fuel tank. (QA) i. Remove tags from FUEL MANAGEMENT panel and fueling control panel.
j.
Perform fuel leak check (WP 004 00). (QA)
k. Install ground plane access door (Figure 1). (QA) l. Close access door F11. (QA)
a. Verify switches on FUEL MANAGEMENT panel are set to CLOSE or OFF and tagged and
006 00
Page 13
006004
Figure 4.
Fuel Quantity Sight Gauge Removal and Installation
13. CENTER SECTION FUEL TANK PILOT VALVE REMOVAL. Support Equipment Required Nomenclature Container, Safety, Fuel, 5 gal Mask, Hose Blower Respirator, Air Line Set, Explosive Gas Detector Type Designation/ Part No. CAGE
006 00
Page 14
Power shall be disconnected from aircraft, static ground cable installed and external power switch tagged before performing fuel system maintenance. Refer to NAVAIR 01-1A-35. c. Rem ov e p ower f ro m ai rc r aft ( NAVAIR 01-75PAA-2-1, WP 010 00). d. Open center section compartment access panel for access to pilot valve connector plug (18, Figure 1). e. Disconnect plug located high on right side of compartment aft bulkhead.
AS02 GGG-M-125/1B, 81348 Type II 72-8001 51906
Materials Required Nomenclature Cord, Nylon Specification/ Part No. MIL-C-5040, Type III
f. Remove pins from connector plug (NAVAIR 01-75PAA-2-15, WP 007 00). g. Attach approximately 10 feet of nylon cord to leads. h. Open access door F11 (11), remove ground plane access door and remove No. 5 fuel tank vent valve access door (10, Figure 5). Remove and discard seal (11). i. Purge fuel tank (NAVAIR 01-1A-35).
NOTE
All fuel cell maintenance shall be consistent with r equirements of NAVAIR 01-1A-35.
a. Defuel No. 5 fuel tank (bladder cell and center section) (NAVAIR 01-75PAA-2-1, WP 011 00). b. Verify switches on FUEL MANAGEMENT panel are set to CLOSE or OFF and tagged and s wi t c he s o n fu e l i n g c o n tr ol p a n e l a re s e t t o CLOSED or OFF and tagged to advise fuel system is not to be operated.
Personnel performing maintenance inside fuel tank shall wear an air-supplied respirator at all times. Fresh air shall be circulated through fuel tank while personnel are inside. Refer to NAVAIR 01-1A-35. No person shall enter a fuel tank unless certified safe for entry by an aviation gas free engineering technician (AVGFET). Refer to NAVAIR 01-1A-35. j. Monitor atmosphere in fuel tank (WP 008 00).
006 00
Page 15/(16 Blank)
Figure 5.
Center Section Fuel Tank and Vent Valve Removal and Installation
006005
k. Disconnect, cap and tag pilot sensing lines (16). Disconnect electrical conduit (12). l. Pull wire harness (13) through conduit (12) until cord shows, then untie cord from leads leaving cord in conduit. m. Turn vent and pilot valves (3, 4) approximately 40 degrees counterclockwise to unlock valves from dome (2) bayonet fitting (1) and pull down, removing both vent and pilot valves from fuel tank. n. Remove bolts (21) and washers (22) securing pilot valve (4) to bracket (29) and remove valve with wire harness (13) attached. o. Loos en nuts (15) on elbows (17) and packings (14) from pilot valve (4) ports. Discard packings. Retain elbows and nuts for installation.
006 00
Page 17
Materials Required Specification/ Part No. MS20995C20 MS20995C32 VV-L-236
a. Verify switches on FUEL MANAGEMENT panel are set to CLOSE or OFF and tagged and s wi t c h es o n fu e l i n g c o n tr o l pa n e l a r e s e t to CLOSED or OFF and tagged to advise fuel system is not to be operated.
NOTE
Note number, type and location of washers to facilitate installation. p. Remove screws (24) and washers (25, 26, 27) securing pilot valve support tube (5) to pilot valve (4). Retain support tube, screws and washers for installation. q. Remove packings (18) from vent valve bayonet fitting (20). Discard packings. 14. CENTER SECTION FUEL TANK PILOT VALVE INSTALLATION.
Power shall be disconnected from aircraft, static ground cable installed and external power switch tagged before performing fuel system maintenance. Refer to NAVAIR 01-1A-35. b. Verify power is removed from aircraft (NAVAIR 01-75PAA-2-1, WP 010 00).
Personnel performing maintenance inside fuel tanks shall wear an air-supplied respirator at all times. Fresh air shall be circulated through the fuel tank while personnel are inside. Refer to NAVAIR 01-1A-35. No person shall enter a fuel tank unless certified safe for entry by an aviation gas free engineering technician (AVGFET). Refer to NAVAIR 01-1A-35. c. Monitor atmosphere in fuel tank (WP 008
Nomenclature Gauge, Feeler Mask, Hose Blower Respirator, Air Line Set, Explosive Gas Detector Wrench, Torque, 0 to 150 lb-ins
00).
PETROLATUM
d. Lubricate packing (18, Figure 5) with petrolatum and install on vent valve bayonet fitting (20). e. Secure pilot valve (4) to bracket (29) on vent valve 3) with bolts (21) and washers (22). (QA)
006 00
Page 18 m. Install packing on plug (8) and install plug in vent valve access door drain flange (7). Secure plug with MS20995C32 lockwire. (QA) n. Install pins in connector plug (18, Figure 1) (NAVAIR 01-75PAA-2-15, WP 007 00). o. Install connector plug (18) and secure with MS20995C20 lockwire. (QA)
PETROLATUM
f. Lubricate packings (14) with petrolatum and install packings and elbows (17) in pilot valve (4) ports and tighten nuts (15). (QA) g. Install pilot valve support tube (5) on pilot valve (4) with correct number and type of washers (25, 26, 27) and screws (24). Using feeler gauge verify gap between flange and screw heads is 0.050 inch. (QA) h. Install valves (3, 4) in fuel tank and position vent valve bayonet fitting (20) in dome bayonet fitting (1) in top of fuel tank. Rotate valves approximately 40 degrees clockwise until bayonet fittings lock. i. Remove caps and connect pilot sensing lines (16) to elbows (17) and attach electrical wiring harness (13) to cord extending from electrical conduit (12). j. Pull wiring harness (13) through electrical conduit (2, Figure 1) into center section compartment. k. Connect electrical conduit (2) to pilot valve fitting (23, Figure 5). (QA)
p. Remove tags from fueling control panel and FUEL MANAGEMENT panel. q. Perform fuel leak check and functional check (WP 004 00). (QA) r. s. Install ground plane access door. (QA) Close access door F11 (11). (QA)
15. CENTER SECTION FUEL TANK VENT VALVE REMOVAL.
Nomenclature Container, Safety, Fuel, 5 gal Mask, Hose Blower Respirator, Air Line Set, Explosive Gas Detector
AS02 GGG-M-125/1B, 81348 Type II 72-8001 51906
Materials Required PETROLATUM 2 Specification/ Part No. MIL-C-5040, Type III
Nomenclature Cord, Nylon
l. Lubricate seal (11) with petrolatum and install on fuel tank vent valve access door (10). Install door with bolts (9). Torque bolts. (QA)
NOTE
All fuel cell maintenance shall be consistent with requirements of NAVAIR 01-1A-35. 00). f.
006 00
Page 19 No person shall enter a fuel tank unless certified safe for entry by an aviation gas free engineering technician (AVGFET). Refer to NAVAIR 01-1A-35. Monitor atmosphere in fuel tank (WP 008
g. Turn valves (3, 4) approximately 40 degrees counterclockwise to unlock valves from dome (2) bayonet fitting (1) and pull down. TURBINE FUEL, AVIATION 1 h. Carefully maneuver valves (3, 4) and pilot valve support tube (5) to a position that permits access to bolts (31) and nuts (28) securing vent valve (3) to bracket (29). i. Remove nuts (28), bolts (31) and washers (30) securing vent valve (3) to bracket (29). j. Remove screws (19) securing vent valve bayonet fitting (20) to vent valve (3). Remove and discard packings (18, 32). Retain vent valve bayonet fitting for installation. 16. CENTER SECTION FUEL TANK VENT VALVE INSTALLATION. Power shall be disconnected from aircraft, static ground cable installed and external power switch tagged before performing fuel system maintenance. Refer to NAVAIR 01-1A-35. c. Remo ve p ower fro m airc raft ( NAVAIR 01-75PAA-2-1, WP 010 00). d. Open access door F11 (11, Figure 1) and remove ground plane access door. Remove bolts (9, Figure 5) securing vent valve access door (10) and remove door. Remove and discard seal (11). e. Purge fuel tank (NAVAIR 01-1A-35). Materials Required Specification/ Part No. MS20995C32 VV-L-236
a. Defuel No. 5 fuel tank (bladder cell and center section) (NAVAIR 01-75PAA-2-1, WP 011 00). b. Verify switches on FUEL MANAGEMENT panel are set to CLOSE or OFF and tagged and s wi t c he s o n fu e l i n g c o n tr ol p a n e l a re s e t t o CLOSED or OFF and tagged to advise fuel system is not to be operated.
Personnel performing maintenance inside fuel tank shall wear an air-supplied respirator at all times. Fresh air shall be circulated through fuel tank while personnel are inside. Refer to NAVAIR 01-1A-35.
a. Verify switches on FUEL MANAGEMENT panel are set to CLOSE or OFF and tagged and s wi t c he s o n fu e l i n g c o n tr ol p a n e l a re s e t t o CLOSED or OFF and tagged to advise fuel system is not to be operated.
006 00
Page 20 h. Position pilot and vent valves (3, 4) so vent valve bayonet fitting (20) is aligned in dome bayonet fitting (1) at top of fuel tank. Rotate valves approximately 40 degrees clockwise until bayonet fittings lock. (QA)
Power shall be disconnected from aircraft, static ground cable installed and external power switch tagged before performing fuel system maintenance. Refer to NAVAIR 01-1A-35. b. Verify power is removed from aircraft (NAVAIR 01-75PAA-2-1, WP 010 00).
PETROLATUM
i. Lubricate seal (11) with petrolatum and install on fuel tank vent valve access door (10) and secure door with bolts (9). j. Install packing on plug (8) and install plug in vent valve access door drain flange (7). Secure plug with MS20995C32 lockwire. (QA) k. Remove tags from fueling control panel and FUEL MANAGEMENT panel. l. Perform fuel leak check and functional check (WP 004 00). (QA) m. Install ground plane access door and close access door F11 (11, Figure 1). (QA) 17. DUMP PUMP REMOVAL, P-3B AIRCRAFT BUNOs 153442 AND SUBSEQUENT AND P-3A AND P-3B AIRCRAFT INCORPORATING AFC 188.
Personnel performing maintenance inside fuel tanks shall wear an air-supplied respirator at all times. Fresh air shall be circulated through the fuel tank while personnel are inside. Refer to NAVAIR 01-1A-35. No person shall enter a fuel tank unless certified safe for entry by an aviation gas free engineering technician (AVGFET). Refer to NAVAIR 01-1A-35. c. Monitor atmosphere in fuel tank (WP 008
00).
Support Equipment Required PETROLATUM d. Lubricate packings with petrolatum. 2 Nomenclature Container, Safety, Fuel, 5 gal Mask, Hose Blower Respirator, Air Line Type Designation/ Part No. CAGE
e. Install packing (32, Figure 5) and vent valve bayonet fitting (20) on vent valve (3) and secure with screws (19). f. Install packings (18) on vent valve bayonet fitting (20). g. Secure vent valve (3) to bracket (29) on pilot valve (4) with bolts (31), washers (30) and nuts (28).
Set, Explosive Gas Detector Tool, Pump Removal and 112-493 Installation
AS02 GGG-M-125/1B, 81348 Type II 72-8001 51906 36659
NOTE
All fuel cell maintenance shall be consistent with requirements of NAVAIR 01-1A-35. a. Defuel No. 5 fuel tank (bladder cell and center section) (NAVAIR 01-75PAA-2-1, WP 011 00). b. At main load center on MAIN AC BUS A aft circuit breaker panel, open and tag FUEL DUMP PUMP circuit breaker and FUEL DUMP CONT and FUEL DUMP VALVE circuit breakers on MAIN DC BUS circuit breaker panel. c. Verify switches on FUEL MANAGEMENT panel are set to CLOSE or OFF and tagged, s wi t c he s o n fu e l i n g c o n tr ol p a n e l a re s e t t o CLOSED or OFF and tagged and FUEL DUMP switch on left outboard overhead panel is set to OFF and tagged to advise fuel system is not to be operated. 1). d. Remove ground plane access door (Figure
006 00
Page 21 h. Release and completely extend sight gauge calibrated slip tube (12). i. While holding wing lower surface access door (5) in position, remove remaining bolts securing door to wing lower surface. j. Carefully remove wing lower surface access door (5) straight down, taking care not to damage packings in sight gauge housing. Push calibrated slip tube back into retracted position. Remove and discard seal from wing lower surface access door. k. Purge fuel tank (NAVAIR 01-1A-35).
Personnel performing maintenance inside fuel tank shall wear an air-supplied respirator at all times. Fresh air shall be circulated through the fuel tank while personnel are inside. Refer to NAVAIR 01-1A-35. No person shall enter a fuel tank unless certified safe for entry by an aviation gas free engineering technician (AVGFET). Refer to NAVAIR 01-1A-35.
Power shall be disconnected from aircraft, static ground cable installed and external power switch tagged before performing fuel system maintenance. Refer to NAVAIR 01-1A-35. e. Re mov e powe r from airc raft ( NAVAIR 01-75PAA-2-1, WP 010 00).
00).
l.
Monitor atmosphere in fuel tank (WP 008
m. Turn pilot and vent valves (3, 4, Figure 5) approximately 40 degrees counterclockwise to unlock valves from dome (2) bayonet fitting (1). n. Carefully maneuver valves (3, 4) and pilot valve support tube (5) to a position out of the way of personnel to gain access to dump pump (7, Figure 1). o. Remove screws and nuts that secure each end of removable cap to center section wing rib across fuel tank access manhole opening. p. Press guide release plate vertically upward and rotate pump removal and installation tool (tool) inner cylinder fully counterclockwise aligning scribe marks on top of tool head (Figure 6). q. Engage detent release in full-down position.
f. Drain No. 5 fuel tank residual fuel into safety fuel container. g. Remove all but four bolts securing wing lower surface access door (5) to aircraft.
006 00
Page 22
006006
Figure 6.
Fuel System Dump Pump Removal and Installation
r. Install tool over pump. Rotate tool until tap aligns with slot in guide cam. s. With tool mounted to pump, rotate tool counterclockwise. Tool rotation to unlock pump is approximately 14 degrees. t. Remove pump.
006 00
Page 23 a. Verify circuit breakers opened during removal procedure are open and tagged. b. Verify switches on FUEL MANAGEMENT panel are set to CLOSE or OFF and tagged, s wi t c h es o n fu e l i n g c o n tr o l pa n e l a r e s e t to CLOSED or OFF and tagged and FUEL DUMP switch on left outboard overhead panel is set to OFF and tagged to advise fuel system is not to be operated. c. Verify power is removed from aircraft (NAVAIR 01-75PAA-2-1, WP 010 00).
u. Disengage tool from pump by pressing guide release plate upward and rotating pump removal tool clockwise. 18. DUMP PUMP INSTALLATION, P-3B AIRCRAFT BUNOs 153442 AND SUBSEQUENT AND P-3A AND P-3B AIRCRAFT INCORPORATING AFC 188.
Support Equipment Required Type Designation/ Part No. CAGE AS02 GGG-M-125/1B, 81348 Type II 72-8001 51906 36659
Personnel performing maintenance inside fuel tanks shall wear an air-supplied respirator at all times. Fresh air shall be circulated through the fuel tank while personnel are inside. Refer to NAVAIR 01-1A-35. No person shall enter a fuel tank unless certified safe for entry by an aviation gas free engineering technician (AVGFET). Refer to NAVAIR 01-1A-35. d. Monitor atmosphere in fuel tank (WP 008 00). e. Press guide release plate vertically upward and rotate pump removal and installation tool (tool) inner cylinder fully counterclockwise, aligning scribe marks on top of tool head (Figure 6).
Set, Explosive Gas Detector Tool, Pump Removal and 112-493 Installation
f.
Rotate cam ring fully clockwise.
g. Verify detent release on tool is in full-up position. (QA) h. Lower tool over pump, aligning slot of inner tool cylinder over electrical plug boss of pump. Hold pump and rotate tool handle counterclockwise until tool snaps and locks to pump. (QA)
NOTE
In this position, the tool and pump do not separate until pump is locked into the pump scroll housing.
i. Install pump into scroll housing guide cam slot. (QA) j. Rotate tool and pump until pump electrical connector aligns with guide cam slot. Pump then drops into the fuel tank-mounted pump scroll housing. (QA) k. With pump lowered into pump scroll housing, rotate tool handle clockwise to lock pump into scroll housing. Rotation to lock is approximately 14 degrees. (QA)
006 00
Page 24 s. Release and completely extend sight gauge calibrated slip tube (12), taking care not to damage packings in sight gauge housing. t. Carefully install wing lower surface access door, verifying that pilot valve support tube (5, Figure 5) correctly engages bolt (6). Secure access door with bolts (9). u. Push calibrated slip tube (12) into fuel tank until tube is seated in support at top of fuel tank. v. Install packing on plug (8) and install plug in vent valve access door drain flange (7). Lockwire plug. (QA) w. Remove tags and close circuit breakers.
NOTE
The pump installation tool cannot be removed unless pump is fully engaged and locked. The motor-impeller assembly of 124470 series pump does not mount or lock into scroll of 124471 series pump. l. Remove tool.
x. Remove tags from FUEL MANAGEMENT panel, fueling control panel and FUEL DUMP switch. y. Perform fuel leak check and functional check (WP 004 00). (QA) z. Install ground plane access door and close access door F11 (11, Figure 1). (QA) 19. CROSSFEED THERMAL RELIEF VALVE REMOVAL.
PETROLATUM
m. Lubricate seal and packings with petrolatum. (QA) n. Position removable cap to center section wing rib fore and aft across fuel tank access manhole opening. o. Secure removable cap to center section wing rib channel with bolts, washers and nuts (two sizes). p. Install packings (18, Figure 5) on vent valve (3) bayonet fitting (20). q. Position vent valve (3) and pilot valve (4) so vent valve bayonet fitting (20) is aligned in dome bayonet fitting (1) at top of fuel tank. Rotate valves approximately 40 degrees clockwise until bayonet fittings lock. (QA) r. Install seal on wing lower surface access door (5, Figure 1).
Nomenclature Container, Safety, Fuel, 5 gal Mask, Hose Blower Respirator, Air Line Set, Explosive Gas Detector
AS02 GGG-M-125/1B, 81348 Type II 72-8001 51906
NOTE
All fuel cell maintenance shall be consistent with requirements of NAVAIR 01-1A-35.
006 00
Page 25 g. Release and completely extend sight gauge calibrated slip tube (12). h. While holding wing lower surface access door (5) in position, remove remaining bolts securing door to wing lower surface. i. Carefully remove wing lower surface access door (5) straight down, taking care not to damage packings in sight gauge housing. Push calibrated slip tube (12) back into retracted position. Remove and discard seal from wing lower surface access door. j. Purge fuel tank (NAVAIR 01-1A-35).
a. Defuel No. 5 fuel tank (bladder cell and center section), (NAVAIR 01-75PAA-2-1, WP 011 00). b . Ve r i f y C R O S S F E E D VA LV E c o n t r o l switches on fuel management panel are set to OFF and tagged to advise fuel system is not to be operated. c. Remove ground plate access door.
Personnel performing maintenance inside fuel tank shall wear an air-supplied respirator at all times. Fresh air shall be circulated through the fuel tank while personnel are inside. Refer to NAVAIR 01-1A-35. No person shall enter a fuel tank unless certified safe for entry by an aviation gas free engineering technician (AVGFET). Refer to NAVAIR 01-1A-35.
Power shall be disconnected from aircraft, static ground cable installed and external power switch tagged before performing fuel system maintenance. Refer to NAVAIR 01-1A-35. d. Re mov e powe r from airc raft ( NAVAIR 01-75PAA-2-1, WP 010 00).
00).
k.
Monitor atmosphere in fuel tank (WP 008
l. Turn pilot and vent valves (3, 4, Figure 5) approximately 40 degrees counterclockwise to unlock valves from dome bayonet fitting (1). m. Carefully maneuver pilot and vent valves (3, 4) and pilot valve support tube (5) to a position out of the way of personnel to gain access to crossfeed thermal relief valve (8, Figure 1). n. Remove screws and nuts that secure each end of removable cap to center section wing rib across fuel tank access manhole opening.
1 o. Remove lockwire from crossfeed fuel sensing transmitter fitting (14) and crossfeed tubing nuts (13) in crossfeed tubes (1, 9) in forward part of fuel tank. p. Disconnect and cap tube to crossfeed fuel sensing transmitter (10) fitting.
e. Drain residual fuel into safety fuel container (NAVAIR 01-75PAA-2-1, WP 011 00). f. Remove all but four bolts securing wing lower surface access door (5, Figure 1) to aircraft.
NOTE
To expedite fitting removal, the crossfeed plumbing shall be loosened. q. Loosen nuts and remove crossfeed fuel sensing transmitter (10) fitting with crossfeed thermal relief valve (8) installed. r. Remove crossfeed thermal relief valve (8) from crossfeed fuel sensing transmitter fitting (14). Remove and discard packing. 20. CROSSFEED THERMAL RELIEF VALVE INSTALLATION. PETROLATUM
006 00
Page 26 b . Ve r i f y C R O S S F E E D VA LV E c o n t r o l switches on FUEL MANAGEMENT panel are set to OFF and tagged to advise system is not to be operated.
c. Lubricate all seals and packings with petrolatum. d. Install packing on crossfeed thermal relief valve (8, Figure 1) and install thermal relief valve in crossfeed fuel sensing transmitter fitting (14). Secure crossfeed thermal relief valve with lockwire. (QA)
Personnel performing maintenance inside fuel tanks shall wear an air-supplied respirator at all times. Fresh air shall be circulated through the fuel tank while personnel are inside. Refer to NAVAIR 01-1A-35. No person shall enter a fuel tank unless certified safe for entry by an aviation gas free engineering technician (AVGFET). Refer to NAVAIR 01-1A-35. 00). e. Monitor atmosphere in fuel tank (WP 008
f. Position crossfeed fuel sensing transmitter fitting in crossfeed plumbing. Install fitting in tubes (1, 9) and lockwire tubing nuts (13). (QA) Tighten plumbing loosened during removal procedure. g. Remove caps and connect tube (10) from fuel sensing transmitter to crossfeed fuel sensing transmitter fitting (14). h. Position removable cap to center section wing rib fore and aft across fuel tank access manhole opening. i. Secure removable cap to center section wing rib channel with bolts, washers and nuts (two sizes).
Power shall be disconnected from aircraft, static ground cable installed and external power switch tagged before performing fuel system maintenance. Refer to NAVAIR 01-1A-35. a. Verify power is removed from aircraft (NAVAIR 01-75PAA-2-1, WP 010 00).
Change 1 - 1 October 1995 j. Install packings (18, Figure 5) on vent valve bayonet fitting (20). k. Position pilot and vent valves (3, 4) so vent valve bayonet fitting (20) is aligned in dome bayonet fitting (1) at top of fuel tank and rotate valves approximately 40 degrees clockwise until bayonet fittings lock. (QA) l. door. Install seal on wing lower surface access
006 00
Page 27/(28 Blank) Figure 5) correctly engages bolt (6). Secure access door with bolts (9). o. Push calibrated slip tube into fuel tank until tube is seated in support at top of fuel tank. p. Install packing on plug (8) and install plug in vent valve access door drain flange (7). Lockwire plug. (QA) q. Remove tags from fueling control panel and FUEL MANAGEMENT panel. r. Perform fuel leak check and functional check (WP 004 00). (QA) s. Install ground plane access door and close access door F11 (11, Figure 1). (QA)
m. Release and completely extend sight gauge calibrated slip tube (12, Figure 1), taking c ar e not to d am age pac ki ng s i n si ght gau ge housing. n. Carefully install wing lower surface access door, verifying that pilot valve support tube (5,
Rapid Action Change 9 - 19 June 1997 ORGANIZATIONAL MAINTENANCE FUSELAGE FUEL (BLADDER) CELL MAINTENANCE AIRCRAFT FUEL SYSTEM
007 00
Page 1
Reference Material Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 002 00 System Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 004 00 Confined Space (Fuel Tank) Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 008 00 Structural Hardware . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . NAVAIR 01-1A-8 Aircraft Fuel Cells and Tanks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . NAVAIR 01-1A-35 Corrosion Control for Aircraft Weapons Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . NAVAIR 01-1A-509 General Information and Servicing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . NAVAIR 01-75PAA-2-1 Line Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 010 00 Fuel System Servicing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 011 00 Airframe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . NAVAIR 01-75PAA-2-2 Corrosion Control, Cleaning, Painting and Decontamination . . . . . . . . . . . . . . . . . . . . NAVAIR 01-75PAA-2-2.1 Connector and Wire Repair Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . NAVAIR 01-75PAA-2-15 Electrical Connector Part Numbers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 007 00 Structural Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . NAVAIR 01-75PAA-3-1 Structural Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . NAVAIR 01-75PAA-3-1.1 Electrical Power Generation and Distribution . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . NAVAIR 01-75PAC-2-13.1 Alphabetical Index Subject Procedures Covered in Other Manuals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removal, Installation and Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Aft Transfer Pump Electrical Conduit and Overboard Drain Installation . . . . . . . . . . . . . . . . . . . . . . . Aft Transfer Pump Electrical Conduit and Overboard Drain Removal . . . . . . . . . . . . . . . . . . . . . . . . . Aft Transfer Pump Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Aft Transfer Pump Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Ball Check Valve and Standpipe Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Ball Check Valve and Standpipe Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Dual Check Valve Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Dual Check Valve Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Forward Transfer Pump Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Forward Transfer Pump Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fuel (Bladder) Cell Drain Mast Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fuel (Bladder) Cell Drain Mast Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fuel (Bladder) Cell Drain Mast Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fuel (Bladder) Cell Drain Valve Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fuel (Bladder) Cell Drain Valve Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fuel (Bladder) Cell Drain Valve Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fuel (Bladder) Cell Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fuel (Bladder) Cell Preservation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fuel (Bladder) Cell Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fuel (Bladder) Cell Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Pilot Valve Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Page No. 2 2 45 43 29 28 42 39 38 37 32 30 52 49 49 49 46 46 18 17 2 17 24
Alphabetical Index (Continued) Subject
007 00
Page 2
Page No. 23 34 34 33 33 28 27
Pilot Valve Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Pump Pressure Switch Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Pump Pressure Switch Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Transfer Pump Pressure Control Valve Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Transfer Pump Pressure Control Valve Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Vent Valve Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Vent Valve Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Record of Applicable Technical Directives
Type/No. AFC 188
Date 2 Mar 70
Title and ECP No. AIRFRAME: Increased Gross Weight and Fuel Dump Capability (ECP 494)
Date Inc. 15 Dec 70
Remarks
1. PROCEDURES COVERED IN OTHER MANUALS. 2. Fuel system maintenance safety procedures are covered in NAVAIR 01-1A-35. Support Equipment Required (Cont) Type Designation/ Part No. CAGE GGG-M-125/1B, 81348 Type II 72-8001 51906
NOTE
NAVAIR 01-1A-35 shall be used in conjunction with and in support of fuel system maintenance procedures contained in this manual. However, if there is a conflict between NAVAIR 01-1A-35 and the maintenance procedures contained in this manual, NAVAIR 01-1A-35 shall take precedence. 3. REMOVAL, INSTALLATION AND INSPECTION. 4. FUEL (BLADDER) CELL REMOVAL.
Nomenclature Respirator, Air Line Set, Explosive Gas Detector
Nomenclature Cloth, Cleaning
Support Equipment Required Type Designation/ Part No. CAGE ZZ-G-381 GG-G-531 AS02 81348 81348
Nomenclature Container, Safety, Fuel, 5 gal Gloves, Rubber, Industrial Goggles, Industrial and Spectacles Mask, Hose Blower
CCC-C-46, Type 1, Class 4 Compound, Corrosion Preventive MIL-C-6529 Cord, Nylon MIL-C-5040, Type III Oil, Lubricating, Jet Engine MIL-L-6081 Talc MIL-T-50036
NOTE
All fuel cell maintenance shall be consistent with requirements of NAVAIR 01-1A-35.
a. Defuel No. 5 fuel tank (bladder cell and center section) (NAVAIR 01-75PAA-2-1, WP 011 00). b. Verify all switches on FUEL MANAGEMENT panel are set to OFF or CLOSE and tagged to advise fuel system is not to be operated. c. At forward load center on MONITORABLE ESSENTIAL AC BUS circuit breaker panel, open and tag FUEL QUANTITY INDICATORS TANK 5 circuit breaker and FUEL TRANSFER PUMP CONT FWD and AFT circuit breakers on EXTENSION MAIN DC BUS circuit breaker panel. d. At main load center, open and tag the following circuit breakers: Name TRANSFER PUMP FWD FUEL BABBBC AFT FUEL TRANS PUMP BABBBC FUEL INLET VALVE CONT fuel tank No. 5 Location MAIN AC BUS A forward circuit breaker panel MAIN AC BUS B forward circuit breaker panel MAIN DC BUS circuit breaker panel TURBINE FUEL, AVIATION
007 00
Page 3 f. Remove power from aircraft (NAVAIR 01-75PAA-2-1, WP 010 00).
g. On lower fuselage, remove FWD FUEL PUMP ACCESS (F107), and AFT FUEL PUMP & FUSELAGE FUEL TANK EQUIPMENT ACCESS (F108) panels. Open FUEL GAGE TRANSMITTER ACCESS (F19) door.
h. On lower fuselage, open center section compartment access panel and adjacent panel for access to bladder cell (27, Figure 1) rear bulkhead fittings (Figure 2).
i. Open FUSELAGE FUEL TANK SUMP DRAIN ACCESS door (F9). Drain residual fuel into safety fuel container and remove water drain valve (73, Figure 3).
Area shall be cleared for bomb bay door movement prior to system operation. Bomb bay door safety pin shall be installed before performing maintenance in bomb bay. e. Open and pin bomb bay doors (NAVAIR 01-75PAA-2-2).
Do not damage or disrupt control cables passing through center section compartment.
j. Disconnect electrical connector (48, Figure 2) from pressure fueling and transfer valve (12).
007 00
Page 4 w. Remove aft transfer pump (19) from fuel tank enough to disconnect aft transfer pump electrical conduit (24, Figure 2) from top of pump.
Pilot valve sensing lines contain residual fuel. A safety fuel container shall be available to drain lines. k. Disconnect pilot valve sensing lines (37, 41) from pressure and transfer valve from pilot valve lines fitting (2). Disconnect pump pressure transmitter lines (68) from pressure switch lines fitting (8). l. Tag lines for reinstallation and cap open ends. Remove unions (43) from pilot valve lines fitting (2) and unions (69) from pressure switch lines fitting (8). m. Remove lockwire from locking bolt (9) and remove bolt (38) and washer (39). n. Rotate valve (12) counterclockwise 90 degrees, then slowly pull valve body from pressure fueling and transfer valve housing (25). o. Disconnect aft transfer pump (14) electrical connector (60), disassemble connector and remove pins (NAVAIR 01-75PAA-2-15, WP 007 00). p. Remove wiring harness seal nut (59) from aft transfer pump electrical conduit fitting (15) and union (62) and remove washers (5, 58) and seal (56). q. Disconnect overboard drain line from aft transfer pump electrical conduit drain fitting (55). r. Remove bolts (31, Figure 1) and washers (30) securing aft transfer pump electrical conduit drain fitting (12) to fuel tank and structure. Remove conduit fitting from wiring harness. s. Remove aft transfer pump cover (34, Figure 3) and pull aft transfer pump screen (36) down and out of fuel tank. t. Disconnect transfer pump scavenge line Wiggins-Type coupling (6) from pump housing (WP 004 00). u. Remove bolts (39) and washers (40) that secure pump discharge fitting (29) to pump housing. v. Remove bolts (37) and washers (38) that secure aft transfer pump (19) to support (17).
x. Remove aft transfer pump (19, Figure 3) from fuel tank pulling wiring harness leads through conduit. y. Remove bolts (16) and washers (15) securing aft transfer pump access cover (14) and gasket (13). Discard gasket. z. Purge bladder cell (NAVAIR 01-1A-35).
Personnel performing maintenance inside fuel tanks shall wear an air-supplied respirator at all times. Fresh air shall be circulated through the fuel tank while personnel are inside. Refer to NAVAIR 01-1A-35. No person shall enter a fuel tank unless certified safe for entry by an aviation gas free engineering technician (AVGFET). Refer to NAVAIR 01-1A-35. aa. Monitor atmosphere in fuel tank (WP 008 00).
Electrical bonding jumpers shall be removed from tubing before removing each section of tubing from bladder cell fuel tank. ab. Remove bolts (64, Figure 2) and washers (63) securing fuel cell to center section fuel tank hose (65) to fuel tank interconnect fitting (17) and cap open end. ac. Remove bolts (18) and washers (19) securing overflow fitting (20) and fuel tank interconnect fitting (17) to structure. ad. Remove bolts (38) and washers (39) securing pressure fueling and transfer valve housing (25) to fuel tank and structure.
007 00
Page 5(6 Blank)
007001
Figure 1.
Bladder Cell Removal and Installation
007 00
Page 7/(8 Blank)
Figure 2.
Bladder Cell Fueling/Transfer Valve Removal and Installation (Sheet 1 of 2)
00700201
007 00
Page 9/(10 Blank)
00700202
Figure 2.
Bladder Cell Fueling/Transfer Valve Removal and Installation (Sheet 2)
007 00
Page 11/(12 Blank)
007003
Figure 3.
Bladder Cell Transfer Pump Removal and Installation
ae. Disconnect transfer pump scavenge lines (49) from scavenge lines fitting (11) unions (50). Remove unions, tag lines for reinstallation and cap open ends. af. Remove and tag forward and aft transfer pump scavenge lines (10, 13), adapter (67) and elbow (54) from scavenge lines fitting. Cap all open ends. ag. Remove bolts and washers securing scavenge lines fitting to structure. ah. Remove bolts (46) and washers (47) attaching fuel cell to center section fuel tank hose (45) to fueling and transfer line fitting (5). Cap hose. ai. Remove bolts (7) and washers (6) that secure fueling and transfer line fitting (5) and fuel dual check valve manifold (4) to structure. aj. Disconnect forward and aft transfer pump pressure transmitter lines (26, 27) from pressure switch lines fitting (8). Disconnect transfer pump pressure transmitter lines (26, 27) at unions (30) from fuel dual check valve manifold (4). Tag lines for reinstallation and cap open ends. ak. Remove bolts (29, Figure 1) and washers (28) attaching pressure switch lines fitting (8, Figure 2) and pilot valve fitting (2) to structure. al. Disconnect electrical connectors for forward transfer pump and pilot valve (8, Figure 4) located at the bomb bay aft bulkhead bladder cell access cover (12). am. Disassemble electrical connector plugs and remove pins from connector plugs (NAVAIR 01-75PAA-2-15, WP 007 00). an. Remove wiring harness seal nuts (17, 18), washers (15, 16, 19) and seals (14, 20) from access plate conduit flanges. ao. Remove forward transfer pump. Refer to FORWARD TRANSFER PUMP REMOVAL this WP. ap. Disconnect Wiggins-Type coupling (49, Figure 3), remove nuts (77), screws (67), washers (66) and clamps (69) securing fueling and defueling line (50) at forward transfer pump (76) support.
007 00
Page 13 aq. Remove screws (18) securing support to forward transfer pump fitting (65) (part of bladder cell). ar. Remove bolts (54) and washers (53) securing sight gauge mounting cover (52). as. Remove fuel quantity capacitance probe (NAVAIR 01-75PAC-2-13.1). at. Remove screws (8, 44), washers (9, 43) and nuts (12, 41) securing two external line support brackets (1, 46) to manhole fitting (11) (part of bladder cell). au. Remove clamps (5) from lines (2, 7) and disconnect Wiggins-Type couplings (6) at the right side of manhole. Remove bonding jumper from each line, tag each line, plug open ends and remove from bladder cell. av. Disconnect aft transfer pump electrical conduit (24, Figure 2) at aft transfer pump electrical conduit fitting (15) union (62) and pull electrical harness through conduit fitting. Remove pump (with conduit attached) from bladder cell. Remove union and discard packing (61). aw. Remove transfer pump lines (3, 28) at fuel dual check valve manifold (4). Tag lines, cap open ends and remove. ax. Disconnect line coupling (31) between fuel dual check valve manifold (4) and pressure fueling and transfer valve housing (25). Remove fuel dual check valve manifold and attach tubing from bladder cell. Cap open ends. ay. Disconnect fueling and defueling line (16) coupling (33) from pressure fueling and transfer valve housing (25) and remove from bladder cell. Cap open ends. az. Remove screws (58, Figure 3), washers (59) and nuts (63) securing support bracket (60) at left side of capacitance fuel probe fitting (51). Tag and remove fueling and defueling line with clamp (61) and bracket (60) from bladder cell. Cap open ends. ba. Remove forward transfer pump scavenge line (2) and forward transfer pump line (7) support bracket (81) at right side of capacitance fuel probe fitting (51). Remove and tag scavenge and transfer lines. Cap open ends.
bb. Untie pilot valve sensing line support straps (76, Figure 2) (nylon cord, three places) and remove from top of bladder cell. bc. Disconnect pilot valve sensing lines (7 Figure 4) from pilot valve (8). Remove lockwire, bolts and washers securing pilot valve sensing line clamp supports to vent dome fitting. Tag lines, cap open ends and remove from bladder cell. bd. Disconnect pilot valve electrical conduit (9) at bladder cell access cover (12) flange and pull wiring harness from the conduit fitting. Untie cord from wiring harness when cord appears at conduit fitting. be. Remove bolts (21) and washers (22) that secure bladder cell access cover at bomb bay aft bulkhead. bf. Remove unions (32) from pressure switch lines fitting (8) and reducers (73) from pilot valve lines fitting (2). Discard packings. bg. Remove vent valve (6) locking bolt (31) and washers (32, 34) located on inboard side of pilot and vent valve bracket (33). bh. Hold pilot and vent valves firmly and turn counterclockwise 90 degrees to unlock vent valve bayonet fitting (5) from dome bayonet fitting (3). bi. Lower valves from bracket and remove vent valve and pilot valve with wiring harness attached. Cap all openings. bj. Remove screws (78, Figure 2), spacers (74) and washers (79) that secure fuel probe damper support (75) and retainer (80) to top of bladder cell. bk. Remove flooring inside cabin at FS 485 from over bladder cell, then remove bolts (34, 37, Figure 1) and washers (35) that secure dome to vent dome fitting (1) and structure. bl. Tag and remove aft transfer pump scavenge line and forward transfer pump scavenge line through the manhole. Cap open ends.
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Page 14
OIL, LUBRICATING, JET ENGINE
bm. Swab entire fuel tank interior surface with oil before leaving fuel tank.
All hardware and components shall be removed before collapsing and rolling bladder cell. bn. Remove all components and hardware.
bo. Remove bolts and washers that secure forward transfer pump fitting (21) to structure. bp. Remove bolts and washers that secure water drain valve fitting (23) to structure. bq. Remove bolts and washers that secure capacitance fuel probe fitting (19) to structure. br. Remove bolts and washers that secure manhole fitting (17) to structure.
Do not proceed with bladder cell removal if temperature is below 10_C (50_F). bs. Through the manhole, work aft section of bladder cell up from structure for access to cord tie points (Figure 1). bt. Untie cords that secure rear bladder cell wall to structure and work forward, untying cords from bladder cell and structure.
All sharp edges of structure or components shall be covered with tape or padding to prevent fuel tank damage.
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Page 15/(16 Blank)
007004
Figure 4.
Bladder Cell Cover Plate and Vent Valve Removal and Installation
bu. As bladder cell is being unstrung, collapse and roll bladder cell and remove through manhole access.
007 00
Page 17
NOTE
All fuel cell maintenance shall be consistent with requirements of NAVAIR 01-1A-35. a. Defuel No. 5 fuel 01-75PAA-2-1, WP 011 00). tank (NAVAIR
COMPOUND, CORROSION PREVENTIVE
bv. With bladder cell outside, unroll, apply corrosion preventive compound to fuel tank fittings and cover all openings with barrier paper or plugs to prevent contamination.
Power shall be disconnected from aircraft, static ground cable installed and external power switch tagged before performing fuel system maintenance. Refer to NAVAIR 01-1A-35. b. Verify that switches on fueling control panel are set to OFF or CLOSED and tagged. c. Verify that switches on FUEL MANAGEMENT panel are set to CLOSE and tagged. d. Verify that FUEL DUMP switch is set to OFF and tagged. e. At forward load center on MONITORABLE ESSENTIAL AC BUS circuit breaker panel, open and tag FUEL QUANTITY INDICATORS TANK 5 circuit breaker and FUEL TRANSFER PUMP CONT FWD and AFT circuit breakers on EXTENSION MAIN DC BUS circuit breaker panel. f. At main load center, open and tag the following circuit breakers: Name TRANSFER PUMP FWD FUEL BABBBC Location MAIN AC BUS A forward circuit breaker panel MAIN AC BUS B forward circuit breaker panel MAIN DC BUS circuit breaker panel
TALC
10
bw. Dust exterior surface of bladder cell with talc before folding. 5. FUEL (BLADDER) CELL REPAIR. Refer to NAVAIR 01-1A-35 for fuel (bladder) cell repair. 6. FUEL (BLADDER) CELL PRESERVATION.
Support Equipment Required Nomenclature Mask, Hose Blower Respirator, Air Line Set, Explosive Gas Detector Type Designation/ Part No. CAGE AS02 GGG-M-125/1B, 81348 Type II 72-8001 51906
Materials Required Nomenclature Cloth, Low-lint Oil, Lubricating, Jet Engine Specification/ Part No. MIL-C-85043, Type II MIL-L-6081 AFT FUEL TRANS PUMP BABBBC FUEL INLET VALVE CONT fuel tank No. 5
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Page 18 m. Lubricate seal and install manhole cover, tightening bolts 180 degrees apart to proper torque value. (QA)
Power shall be disconnected from aircraft, static ground cable installed and external power switch shall be off and tagged before performing fuel system maintenance. Refer to NAVAIR 01-1A-35. g. Verify power is removed from aircraft (NAVAIR 01-75PAA-2-1, WP 010 00). h. Remove aft fuel transfer pump to gain access to interior of bladder. Refer to AFT TRANSFER PUMP REMOVAL this WP. i. j. Remove manhole cover. Purge bladder cell (NAVAIR 01-1A-35).
n. Perform AFT TRANSFER PUMP INSTALLATION this WP. (QA)
NOTE
Depreservation is not required prior to adding fuel to fuel cell. 7. FUEL (BLADDER) CELL INSTALLATION.
Support Equipment Required Type Designation/ Part No. CAGE ZZ-G-381 GG-G-531 81348 81348
Nomenclature Personnel performing maintenance inside fuel tanks shall wear an air-supplied respirator at all times. Fresh air shall be circulated through the fuel tank while personnel are inside. Refer to NAVAIR 01-1A-35. No person shall enter a fuel tank unless certified safe for entry by an aviation gas free engineering technician (AVGFET). Refer to NAVAIR 01-1A-35. k. Monitor atmosphere in fuel tank (WP 008 00). Gloves, Rubber, Industrial Goggles, Industrial and Spectacles Mask, Hose Blower Respirator, Air Line Set, Explosive Gas Detector Wrench, Torque, 100 to 750 lb-ins
AS02 GGG-M-125/1B, 81348 Type II 72-8001 51906
Materials Required OIL, LUBRICATING, JET ENGINE 8 Nomenclature Specification/ Part No.
l. Using care not to damage bladder interior, fuel probes or other internal fuel tank fittings, spray inner surfaces liberally with oil. If spray equipment is not available, the bladder interior may be wiped with a lint-free cloth saturated with oil. Extra care shall be taken to avoid damage or contamination during wiping.
Adhesive, Rubber MIL-A-5092 Compound, Sealing, Polysulfide, MIL-S-8802, Type II for Brush Application Cord, Nylon MIL-C-5040, Type III Petrolatum VV-L-236
Materials Required (Cont) Specification/ Part No. MS20995C20 MS20995C32 No. 130AA MIL-T-50036 PPP-T-60 ADHESIVE, RUBBER
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Page 19
Nomenclature Lockwire Lockwire Lubriplate Talc Tape
11
d. Replace all gaskets at top, bottom forward bulkhead and aft bulkhead fuel tank cavity openings. Use adhesive to secure gaskets (Figure 1).
TALC Power shall be disconnected from aircraft, static ground cable installed and external power switch tagged before performing fuel system maintenance. Refer to NAVAIR 01-1A-35 a. Verify power is removed from aircraft (NAVAIR 01-75PAA-2-1, WP 010 00).
10
e. Dust fuel tank cavity and bladder cell (27, Figure 1) with talc. (QA) f. Roll replacement bladder cell and insert into fuel tank cavity through manhole access. g. Position bladder cell to fuel tank cavity.
Do not attempt bladder cell installation if temperature is below 10_C (50_F). Do not fold cell. b. Verify that switches on fueling control panel are set to OFF or CLOSED and tagged and that switches on FUEL MANAGEMENT panel are set to CLOSE and tagged.
h. Fabricate new lacing cords from nylon cord, cutting cords to approximately twice measured span to be laced. i. Start cord tie at forward bulkhead lower tie rings and lace fuel tank wall to bulkhead securely. j. Tie top, side and bottom bladder cell cords to forward bulkhead tie rings and loosely lace bladder cell to fuel tank cavity walls. k. Tie bladder cell aft bulkhead cords to top tie rings on aft bulkhead and loosely lace bladder cell to fuel tank cavity wall. l. Pull all cords tightly so bladder cell is held against fuel tank cavity walls. Start at top bladder cell. (QA) m. Securely tie cord ends to prevent unraveling of cord. (QA)
Tape and padding shall be used to cover all protrusions into fuel tank cavity which could damage bladder cell. c. Inspect fuel tank cavity and verify that all sharp edges, corners, cutouts, rivet heads and joints, all machined surfaces, screws, bolts, nuts and other protrusions which could damage the bladder cell are padded or covered with tape. (QA)
NOTE
Unless specifically directed otherwise, all bolts use standard torque values. Refer to WP 002 00. n. Attach bladder cell manhole fitting (17) to structure with bolts and washers at fore and aft, left and right mount bolt positions. (QA) o. Install capacitance fuel probe fitting (19) to structure with bolts and washers. (QA) p. Install forward transfer pump fitting (21) to structure with bolts and washers. (QA) q. Install water drain valve fitting (23) to structure with bolts and washers and tighten. (QA) r. Install pilot and float vent valve access fitting (25) to structure with bolts and washers. (QA)
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Page 20
Electrical bonding jumpers shall be electrically bonded and connected to tubing after installation of each piece of tubing (NAVAIR 01-75PAA-3-1). v. Install support brackets (1, 46, Figure 3) on manhole fitting (11) with screws (8, 44), washers (9, 45) and nuts (12, 41). (QA) w. Install fuel probe damper support (5, Figure 2) and retainer (80) with screws (8) and washers (9), at top center of fuel tank. (QA) x. Install pilot valve sensing lines (1, 29) at top of fuel tank with attaching nylon cord to fuel tank support straps (76). Install forward transfer pump scavenge line and forward transfer lines (2, 7, Figure 3) support bracket (81) with clamps (80) to right side of the capacitance fuel probe fitting (51) and support bracket (1) at manhole fitting (11). (QA) y. Install fueling and defueling line (50) with support bracket (60) and clamp (61) to left side of capacitance fuel probe fitting and support bracket (46) at manhole fitting. (QA) z. Install forward transfer pump (76) support (17) on forward transfer pump fitting (65) with screws (18). aa. Install packings (4, Figure 4) on vent valve bayonet fitting (5) and insert valve in dome (2) engaging vent valve bayonet fitting and dome bayonet fitting (3) with screws (23). (QA) ab. Hold pilot valve (8) and vent valve (6) firmly and turn clockwise 90 degrees to lock valves securely in dome (2). (QA) ac. Install vent valve locking washers (32, 34) and bolt (31) at left side of pilot and vent valve bracket (33). ad. Install pilot valve sensing lines (7) to elbows (27) at pilot valve (8). (QA)
PETROLATUM
s. Coat all packings with petrolatum prior to installation. t. Install vent dome fitting (1) with packing (2) at fuel tank top opening at cabin access FS 485, with bolts (34, 37) and washers (35). (QA)
Personnel performing maintenance inside fuel tanks shall wear an air-supplied respirator at all times. Fresh air shall be circulated through the fuel tank while personnel are inside. Refer to NAVAIR 01-1A-35. No person shall enter a fuel tank unless certified safe for entry by an aviation gas free engineering technician (AVGFET). Refer to NAVAIR 01-1A-35. u. Monitor atmosphere in fuel tank (WP 008 00).
ae. Attach cord to pilot valve electrical harness and pull cord through flange of bladder cell access cover (12). Do not attach pilot valve electrical conduit (9) to access cover at this time. af. Position pressure fueling and transfer valve housing (25, Figure 2) with ball check valve (21) and standpipe (23) attached at rear wall in fuel tank aligning pressure fueling and transfer valve housing and overflow fitting (20) with fueling and transfer line fitting (5) and fuel tank interconnect fitting (17). ag. Install packing in fuel tank interconnect fitting groove and attach overflow fitting (20) to bladder cell and structure from center section compartment with bolts (18) and washers (19). (QA) ah. Install packing at pressure fueling and transfer valve housing and attach housing from center section compartment with bolts (38) and washers (39). (QA) ai. Position fuel dual check valve manifold (4) with plumbing attached in fuel tank and align check valve with fueling and transfer line fitting (5) and fueling transfer valve housing. aj. Install packing on fuel dual check valve manifold (4) and attach valve to fuel tank and structure from center section compartment with bolts (7) and washers (6). (QA) ak. Install aft transfer pump electrical conduit drain fitting (12, Figure 1) to fuel tank with gaskets (13, 14) and attach fitting from center section compartment with bolts (31) and washers (30). (QA) al. Connect fuel dual check valve manifold (4) to pressure fueling and transfer valve housing (25, Figure 2) coupling (31). (QA) am. Install transfer pump pressure transmitter line unions (30) with packings in fuel dual check valve manifold (4) and fueling and transfer line fittings. Install transfer pump pressure transmitter lines (26, 27). (QA) an. Perform FORWARD TRANSFER PUMP INSTALLATION this WP. ao. Pull cord attached to forward transfer pump electrical harness through wiring harness flange of bladder cell access cover (12, Figure 4).
007 00
Page 21 ap. Install bladder cell access cover, with packing, at the bomb bay aft bulk-head with bolts (21) and washers (22). Secure bolts with MS20995C32 lockwire. (QA)
LUBRIPLATE aq. Apply lubriplate to conduit nut.
ar. Torque nut to 400 pound-inches. Loosen and torque nut from 360 to 440 pound-inches. (QA) as. Pull pilot valve (8) and forward transfer pump harnesses through conduit flanges at the bomb bay aft bulkhead bladder cell access cover. Install pilot valve conduit seal (20) and pump conduit seal (14), washers (15, 16, 19) and nuts (17, 18). Secure nuts with MS20995C32 lockwire. (QA) at. Remove cord from both harnesses and reassemble electrical connectors for forward transfer pump (76, Figure 3) and pilot valve (8, Figure 4) (NAVAIR 01-75PAA-2-15, WP 007 00). au. Connect pilot valve and forward transfer pump electrical connector plugs to receptacles. av. Install fueling and defueling line (50, Figure 3) to support bracket (68) and connect couplings (6, 49). aw. Install aft transfer pump scavenge line (13, Figure 2) and forward transfer pump scavenge line (10) in fuel tank. (QA) ax. Install scavenge line unions (50), adapter (67) and elbow (54) with packings (52) in scavenge line fitting (11) and attach internal scavenge lines to fitting. (QA) ay. Connect forward transfer pump transfer line coupling (6, Figure 3) and clamp (5) to plumbing support bracket (1) at right side of manhole. az. Connect forward transfer pump scavenge line coupling (6) adjacent to transfer line and secure clamp (5) to plumbing support bracket (1). (QA)
ba. Connect fueling and defueling line coupling (49) and secure clamp (48) to plumbing support bracket (46) at left side of manhole. (QA) bb. Install pilot valve lines fitting (2, Figure 2) and pressure switch lines fitting (8) to structure with bolts and washers in center section compartment. (QA) bc. Install reducers (73) and unions (43) with packings (72, 42) and install pilot valve sensing lines (37, 41) in fuel tank at pilot valve line fitting (2) in fuel tank rear wall. (QA) bd. Install pump pressure transmitter line unions (32, 69) with packings (70, 71) in pressure switch lines fitting (8) and install transmitter lines to fitting. (QA) be. Install packing (44) and attach fuel cell to center section fuel tank hose (45) to fueling and transfer line fitting (5) with bolts (46) and washers (47). (QA) bf. Install scavenge line fitting (11) in fuel tank rear wall with bolts and washers. (QA) bg. Install packings (51) on transfer pump scavenge lines (49) and connect scavenge lines to scavenge line fitting (11). bh. Install packing (66) at fuel tank interconnect fitting (17) and install fuel cell to center section fuel tank hose (65) with bolts (64) and washers (63). (QA) bi. Install packing (61) on union (62) and install in aft transfer pump electrical conduit fitting (15) on bladder cell rear wall.
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Page 22
bl. Apply sealing compound to all fuel lines electrical bonding jumpers (NAVAIR 01-75PAA-3-1). bm. Inspect fuel tank for cleanliness. Remove all contaminants. bn. Install packing (74, Figure 3) on water drain valve (73) and position drain valve on water drain valve fitting (75). (QA) bo. Secure water drain valve (73) in position with four bolts and washers. bp. Install packing on hex cover adjacent to fuel probe mount and attach cover to structure. (QA)
Use extreme care when handling fuel quantity probes. bq. Install packing on fuel quantity transmitter probe and insert probe in fuel tank so probe mates with damper and retainer at top of fuel tank. (QA) br. Install probe to fuel tank with bolts. (QA)
LUBRIPLATE
bj. Lubricate conduit nut of aft transfer pump electrical conduit (24) with lubriplate. bk. Torque nut to 400 pound-inches. Loosen and torque nut from 360 to 440 pound-inches. (QA)
bs. Install fuel quantity probe electrical connection as tagged and install terminal protective cover. Secure cover bolts with MS20995C20 lockwire. (QA) bt. Install packing on pressure fueling and transfer valve (12, Figure 2) body.
bu. Install pressure fueling and transfer valve (12) in pressure fueling and transfer valve housing (25). bv. Align indexing pin on valve body with indexing hole on valve housing and insert valve body straight into valve housing. (QA) bw. Insert valve body until bayonet lock bottoms in housing, then rotate valve clockwise 90 degrees to lock. bx. Install positioning lock bolt (9) and washer (39) and secure with MS20995C32 lockwire. (QA) by. Install pilot valve sensing lines (37, 41) according to identification tag. (QA) bz. Install electrical connector (4) to pressure fueling and transfer valve receptacle. ca. Perform final inspection of fuel tank interior. Verify that all components except aft transfer pump are installed and secure and interior of bladder cell is clean. (QA) cb. Pass nylon cord through aft transfer pump electrical conduit (24). cc. Install seal on manhole cover and secure cover in place with bolts and tighten, using 180 degree tightening sequence. (QA) cd. Perform AFT TRANSFER PUMP INSTALLATION this WP. (QA) ce. Install overboard drain line at aft transfer pump electrical conduit drain fitting (55). cf. cg. panel. Remove tags and close circuit breakers. Remove tag from FUEL MANAGEMENT Nomenclature Cord, Nylon
007 00
Page 23 ck. Close FUSELAG E FUEL TANK SUMP DRAIN ACCESS door (F9).
Before operating bomb bay doors, the immediate area shall be clear of personnel and maintenance equipment. cl. Close 01-75PAA-2-2). bomb bay doors (NAVAIR
8. PILOT VALVE REMOVAL.
a. Defuel No. 5 fuel tank (bladder cell and center section) (NAVAIR 01-75PAA-2-1, WP 011 00).
Power shall be disconnected from aircraft, static ground cable installed and external power switch tagged before performing fuel system maintenance. Refer to NAVAIR 01-1A-35. b. Verify that switches on fueling control panel are set to OFF or CLOSED and tagged. c. Verify that switches on FUEL MANAGEMENT panel are set to CLOSE and tagged.
ch. Perform fuel leak check and functional check (WP 004 00). (QA) ci. On lower fuselage, install FWD FUEL PUMP ACCESS (F107), AFT FUEL PUMP and FUSELAGE FUEL TANK EQUIPMENT ACCESS (F108) panels. Close FUEL GAUGE TRANSMITTER ACCESS (F19) door. cj. On lower fuselage, close and secure center section compartment access panel and adjacent panel.
The area shall be cleared for bomb bay door movement prior to system operation. The bomb bay door safety pin shall be installed before performing maintenance in the bomb bay.
d. Open and pin bomb bay doors (NAVAIR 01-75PAA-2-2). e. Remove power from aircraft (NAVAIR 01-75PAA-2-1, WP 010 00). f. Disconnect forward fuel transfer pump and pilot valve connector plugs at bomb bay aft bulkhead. g. Remove pins from valve connector plug (NAVAIR 01-75PAA-2-15, WP 007 00). h. ture. Remove clips securing wire bundles to struc-
007 00
Page 24 o. Loosen lock bolt (14) in center of bracket (17) and pull pilot valve (4) forward to stop. p. Grasp pilot valve (4) firmly, push up and pull forward, then pull down to remove valve from bracket (17). q. Remove pilot valve (4) with conduit and electrical leads attached from fuel tank, through access cover opening. r. Remove electrical conduit (5) from pilot valve (4) and pull wire harness (6) from electrical conduit and access cover. Remove packing (13, Figure 4) from access cover. Discard packing. s. Untie cord from pilot valve (4, Figure 5) wire harness; leave cord extending through fuel tank access cover for use in installing wires. t. Loosen nuts (8) and remove elbows (10) and packings (7). Discard packings. 9. PILOT VALVE INSTALLATION. Support Equipment Required Nomenclature Wrench, Torque, 100 to 750 lb-ins Type Designation/ Part No. CAGE
i. Disconnect wiring harness seal nuts (17, 18, Figure 4) at bladder cell access cover (12) and remove conduit washers (15, 16, 19) and seals (14, 20) from access cover. j. Tie cord, approximately 6 feet long, to wiring harness.
Power shall be disconnected from aircraft, static ground installed and external power switch tagged before performing fuel system maintenance. Refer to NAVAIR 01-1A-35. k. Remove access cover bolts.
l. Use three bolts, approximately 3 inches long, positioned 120 degrees apart to install fuel tank access cover and slide cover forward on bolts. m. Disconnect pilot valve and forward transfer pump electrical conduits (9, 11) on fuel tank side of access cover, remove bolts installed in step l and swing cover to the side. Remove and discard packing (10) from pilot valve electrical conduit. n. Disconnect pilot valve sensing lines (9, Figure 5) from pilot valve (4) and install caps.
Materials Required Nomenclature Lockwire Lubriplate Petrolatum Specification/ Part No. MS20995C32 No. 130AA VV-L-236
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Page 25
Figure 5.
Pilot and Vent Valve Removal and Installation
007005
007 00
Page 26 i. Attach cord from access cover through electrical conduit (5) to pilot valve (4) wire harness (6). Pull wire harness through electrical conduit.
Power shall be disconnected from aircraft, static ground installed and external power switch tagged before performing fuel system maintenance. Refer to NAVAIR 01-1A-35. a. Verify power is removed from aircraft (NAVAIR 01-75PAA-2-1, WP 010 00). b. Verify that switches on fueling control panel are set to OFF or CLOSED and tagged and that switches on FUEL MANAGEMENT panel are set to CLOSE and tagged.
LUBRIPLATE
j. Lubricate pilot valve (4) electrical conduit (5) nut with lubriplate. k. Install electrical conduit (5) nut onto pilot valve fitting (16). l. Insert pilot valve (4) in bladder cell with pilot valve fitting (16) facing forward. m. Guide pilot valve (4) mounting screws (15) up into slots in bracket (17) and push pilot valve against stop. n. While holding pilot valve (4) aft against stop, tighten lock bolt (14). o. Remove caps and connect pilot valve sensing lines (9) to elbows (10). Tighten nuts (8). p. Pull transfer pump wire harness through access cover.
PETROLATUM
c. Lubricate packing (13, Figure 4) with petrolatum and install in access cover (12). d. Install mounting screws (15, Figure 5) on pilot valve (4). e. Install nuts (8) on elbows (10).
PETROLATUM
2 LUBRIPLATE 3 q. Lubricate forward transfer pump electrical conduit (11, Figure 4) nut with lubriplate. r. Use three bolts, approximately 3 inches long, positioned 120 degrees apart to hold access cover to bladder cell fitting. s. Thread transfer pump electrical conduit nut on access cover flange. t. Torque nut to 400 pound-inches; loosen and torque nut to 360 to 440 pound-inches. (QA)
f. Lubricate packings (7) with petrolatum and install on elbows (10). g. Install elbows (10) in pilot valve (4). Do not tighten nuts at this time.
PETROLATUM
h. Lubricate packing with petrolatum and install on electrical conduit (5).
u. Connect pilot valve electrical conduit to access cover flange. Bond faying surface (Figure 4). v. Remove 3 inch holding bolts. Install access cover with bolts and washers. Secure bolts using MS20995C32 lockwire. (QA) w. Install seal (20), washer (19) and nut (18) on pilot valve electrical conduit. Seal wire harness in seal and tighten nut. Lockwire nut. (QA) x. Install seal (14), washer (15), washer (16) and nut (17) on transfer pump wire harness. Seal wire harness in seal and tighten nut. (QA) y. Install pins in connector plug ( NAVAIR 01-75PAA-2-15, WP 007 00). z. Attach wire bundles to structure with five clips and connect plugs to receptacles. aa. Perform fuel leak check and functional check (WP 004 00). (QA)
007 00
Page 27
NOTE
Before operating bomb bay doors, personnel and maintenance equipment shall be removed from immediate area. ab. Close bomb bay doors ( NAVAIR 01-75PAA-2-2) and remove tags from fueling control and FUEL MANAGEMENT panels. ac. Remove power from aircraft (NAVAIR 01-75PAA-2-1, WP 010 00). 10. VENT VALVE REMOVAL. Materials Required Nomenclature Cord, Nylon Specification/ Part No. MIL-C-5040, Type III
Before operating bomb bay doors, personnel and equipment shall be removed from immediate area. The bomb bay door safety pin shall be installed before performing maintenance in the bomb bay. d. Open and pin bomb bay doors (NAVAIR 01-75PAA-2-2). e. Remove power fr om air craft (NAVAIR 01-75PAA-2-1, WP 010 00). f. Remove bladder cell pilot valve. Refer to PILOT VALVE REMOVAL this WP. g. Remove vent valve locking bolt (29, Figure 4) located on in board side of pilot and vent valve bracket stop (28).
h. Hold vent valve (3, Figure 5) firmly and turn counterclockwise 90 degrees to unlock. i. cell. Pull vent valve (3) and remove from bladder Nomenclature Cord, Nylon Materials Required
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Page 28
Specification/ Part No. MIL-C-5040, Type III
11. VENT VALVE INSTALLATION.
NOTE
Power shall be disconnected from aircraft, static ground cable installed and external power switch tagged before performing fuel system maintenance. Refer to NAVAIR 01-1A-35. a. Remove power from aircraft (NAVAIR 01-75PAA-2-1, WP 010 00). b. Verify that switches on fueling control panel are set to OFF or CLOSED and tagged and that switches on FUEL MANAGEMENT panel are set to CLOSE and tagged. c. Insert vent valve (3, Figure 5) into fuel tank through bomb bay aft bulkhead fuel tank access door, guide valve into upper fitting of dome (2) and turn clockwise 90 degrees to lock in position. (QA) d. Slide pilot and vent valve stop forward and install vent valve locking bolt (29, Figure 4) at stop inboard side. (QA) e. Install bladder cell pilot valve. Refer to PILOT VALVE INSTALLATION this WP. (QA) f. Perform functional check (WP 004 00). (QA) TRANSFER PUMP FWD FUEL BABBBC AFT FUEL TRANS PUMP BABBBC FUEL DUMP PUMP All fuel cell maintenance shall be consistent with requirements of NAVAIR 01-1A-35. a. Defuel No. 5 fuel tank (bladder cell and center section fuel tank) (NAVAIR 01-75PAA-2-1, WP 011 00). b. Verify that FWD and AFT TRANSFER PUMP control switches on FUEL MANAGEMENT panel are OFF and tagged, and FUEL PUMP switch is tagged. c. At forward load center on EXTENSION MAIN DC BUS circuit breaker panel, open and tag FUEL TRANSFER PUMP CONT FWD and AFT circuit breakers. d. At main load center, open and tag the following circuit breakers: Name FUEL DUMP CONT FUEL DUMP VALVE Location MAIN DC BUS circuit breaker panel MAIN DC BUS circuit breaker panel MAIN AC BUS A forward circuit breaker panel MAIN AC BUS B forward circuit breaker panel MAIN AC BUS A aft circuit breaker panel
12. AFT TRANSFER PUMP REMOVAL. Support Equipment Required Nomenclature Wrench, Spanner Type Designation/ Part No. CAGE
13.
007 00
Page 29 AFT TRANSFER PUMP INSTALLATION.
Electrical power shall be disconnected from aircraft, static ground cable installed and external power switch tagged before performing fuel system maintenance. e. Remove power from aircraft ( NAVAIR 01-75PAA-2-1, WP 010 00). f. Open AFT FUEL PUMP and FUSELAGE FUEL TANK EQUIPMENT ACCESS (F108) and center section compartment access panels. g. Remove aft transfer pump cover (34, Figure 3) and pull aft transfer pump screen (36) down and out of fuel tank. h. Disconnect transfer pump scavenge line Wiggins type coupling (6) from pump housing (WP 004 00). i. Remove bolts (39) and washers (40) that secure pump discharge fitting to pump housing. j. Remove bolts (37) and washers (38) that secure pump (19) to support (17). k. Disconnect aft transfer pump wiring electrical connector (60, Figure 2) and remove clips that secure wire bundle to structure in center section compartment. l. Remove pins from connector plug (NAVAIR 01-75PAA-2-15, WP 007 00). m. Remove aft transfer pump electrical conduit (24) seal nut (59), washers (58, 57) and seal (56). n. Attach wiring leads to cord approximately 10 feet long. o. Remove pump from fuel tank enough to disconnect electrical conduit from top of pump. p. Remove pump from fuel tank pulling wiring leads through conduit. q. Untie cord from wiring leads.
Nomenclature Wrench, Spanner Wrench, Torque, 100 to 750 lb-ins
Materials Required Specification/ Part No. MS20995C20 MS20995C32 No. 130AA VV-L-236
Nomenclature Lockwire Lockwire Lubriplate Petrolatum
Power shall be disconnected from aircraft, static ground cable installed and external power switch tagged before performing fuel system maintenance. Refer to NAVAIR 01-1A-35. a. Verify power is removed from aircraft (NAVAIR 01-75PAA-2-1, WP 010 00). b. Verify that switches on fueling control panel are set to OFF or CLOSED and tagged and that switches on FUEL MANAGEMENT panel are set to CLOSE and tagged. c. Verify FUEL DUMP switch is set to OFF.
d. Verify circuit breakers opened during removal procedure are open and tagged. e. Attach cord from aft transfer pump electrical conduit (24, Figure 2) in fuel tank to wire leads on replacement pump.
f. Pull cord and wiring through conduit from the center section compartment.
007 00
Page 30 q. Attach wire bundle to structure with clips and connect plug connector. Secure connector with MS20995C20 lockwire. (QA) r. Remove tags from fueling control panel, FUEL MANAGEMENT panel and FUEL DUMP switch. s. Remove tags and close circuit breakers.
LUBRIPLATE
g. Lubricate conduit assembly nut with lubriplate and attach conduit to top of pump. h. Torque nut to 40040 pound-inches. (QA)
t. Perform fuel leak check and functional check (WP 004 00). (QA) u. Close center section compartment access panels and AFT FUEL PUMP and FUSELAGE FUEL TANK EQUIPMENT ACCESS (F108) panel. 14. FORWARD TRANSFER PUMP REMOVAL.
i. Position pump to align couplings and install aft transfer pump (19, Figure 3) on pump support (17) with bolts (37) and washers (38).
PETROLATUM
2 Support Equipment Required Type Designation/ Part No. CAGE
j. Lubricate packing (20) with petrolatum and install on pump discharge fitting (29). Secure to pump with bolts (39) and washers (40). k. Lubricate packings with petrolatum and install at pump scavenge line Wiggins-Type coupling (6) and s ec ur e to pump (WP 004 00). Secure with MS20995C32 lockwire. (QA) l. (QA) Position pump screen (36) in pump support.
Nomenclature Wrench, Spanner
Nomenclature PETROLATUM 2 Cord, Nylon
m. Lubricate packing (35) with petrolatum and install on pump cover (34) and install with bolts (32) and washers (33). n. Remove cord from pump harness leads in center section service bay compartment. o. Install conduit seal (56, Figure 2), washers (57, 58) and nut (59) on aft transfer pump electrical c onduit drain fitting (55). Secure nut with MS20995C32 lockwire. (QA) p. Ins tall pins in connec tor plug (NAVAIR 01-75PAA-2-15, WP 007 00).
NOTE
All fuel cell maintenance shall be consistent with requirements of NAVAIR 01-1A-35. a. Defuel No. 5 fuel tank (bladder cell and center section) (NAVAIR 01-75PAA-2-1, WP 010 00). b. Verify FWD and AFT TRANSFER PUMP switches on FUEL MANAGEMENT panel and FUEL DUMP switch are set to OFF and tagged.
c. At forward load center on EXTENSION MAIN DC BUS circuit breaker panel, open and tag FUEL TRANSFER PUMP CONT FWD and AFT circuit breakers. d. At main load center, open and tag the following circuit breakers:
007 00
Page 31 j. Remove electrical conduit nut (17, Figure 4), washers (16, 15) and seal (14). k. Attach approximately 10 feet of cord to electrical harness.
Name FUEL DUMP CONT FUEL DUMP VALVE TRANSFER PUMP FWD FUEL BABBBC AFT FUEL TRANS PUMP BABBBC FUEL DUMP PUMP
Location MAIN DC BUS circuit breaker panel MAIN DC BUS circuit breaker panel MAIN AC BUS A forward circuit breaker panel MAIN AC BUS B forward circuit breaker panel MAIN AC BUS A aft circuit breaker panel
Power shall be disconnected from aircraft, static ground cable installed and external power switch tagged before performing fuel system maintenance. Refer to NAVAIR 01-1A-35. l. Remove bladder cell access cover (12) bolts (31) and washers (22). m. Use three bolts, approximately 3 inches long, positioned 120 degrees apart, to install bladder cell access cover and slide cover forward on bolts. n. Disconnect forward transfer pump electrical conduit (11) from fuel tank side of access cover.
The area shall be cleared for bomb bay door movement before system operation. The bomb bay door safety pin shall be installed before performing maintenance in the bomb bay. e. Open and pin bomb bay doors (NAVAIR 01-75PAA-2-2). f. Remove power from aircraft ( NAVAIR 01-75PAA-2-1, WP 010 00). g. Open FWD FUEL PUMP ACCESS door (F107). h. Disconnect forward fuel transfer pump connector plug at bomb bay aft bulkhead. i. Remove clips securing electrical harness to structure and remove pins from connector (NAVAIR 01-75PAA-2-15, WP 007 00).
o. Remove forward transfer pump (76, Figure 3) aft transfer pump cover (34) and pull screen (36) down and out of fuel tank. p. Disconnect pump of forward transfer scavenge line (2) Wiggins-Type coupling (6) (WP 004 00). q. Remove bolts (39) and washers (40) securing pump discharge fitting (29) to pump (19) housing. r. Remove bolts (37) and washers (38) securing pump (19) to support (17). s. Turn pump (19) and remove from fuel tank, pulling conduit and harness with cord attached. t. Remove cord from electrical harness.
15. FORWARD TRANSFER PUMP INSTALLATION.
007 00
Page 32 d. Lubricate electrical conduit assembly nut with lubriplate. e. Torque nut 40040 pound-inches. (QA)
Nomenclature Wrench, Spanner Wrench, Torque 100 to 750 lb-ins
f. Position pump (76, Figure 3) on support (17), attaching electrical harness to cord protruding from fuel tank and secure pump to support with washers (38) and bolts (37).
PETROLATUM Materials Required Specification/ Part No. MS20995C20 MS20995C32 No. 130AA VV-L-236
Nomenclature Lockwire Lockwire Lubriplate Petrolatum
g. Lubricate packing (20) with petrolatum and install at pump discharge fitting (29) and secure fitting with washers (40) and bolts (39). h. Lubricate packings (25) with petrolatum and install at pumps scavenge line (2) Wiggins-Type coupling (6) and secure to pump (WP 004 00). (QA) i. Position pump screen (36). (QA)
Power shall be disconnected from aircraft, static ground cable installed and external power switch tagged before performing fuel system maintenance. Refer to NAVAIR 01-1A-35. a. Remove power from aircraft (NAVAIR 01-75PAA-2-1, WP 010 00). b. Verify FUEL MANAGEMENT panel switches and FUEL DUMP switch are tagged and that circuit breakers opened during removal procedure are open and tagged. c. Install forward transfer pump electrical conduit (11, Figure 4) on pump with pump electrical harness extending from conduit.
PETROLATUM
j. Lubricate packing (35) with petrolatum and install on pump cover (34). Secure cover in place with washers (33) and bolts (32). k. Lubricate packing (13, Figure 4) with petrolatum and install on bladder cell access cover (12). l. At bomb bay access to fuel tank use three bolts, approximately 3 inches long, positioned 120 degrees apart, to hold bladder cell access cover while attaching pump conduit cover.
LUBRIPLATE
LUBRIPLATE
m. Lubricate electrical conduit assembly nut with lubriplate.
n. Torque nut to 40040 pound-inches. (QA)
007 00
Page 33 d. Remove power fr om air craft (NAVAIR 01-75PAA-2-1, WP 010 00). e. Remove applicable transfer pump from bladder cell. Refer to AFT TRANSFER PUMP REMOVAL or FORWARD TRANSFER PUMP REMOVAL this WP as applicable. f. Remove lockwire from fuel pressure control valve (22, Figure 3) located on transfer pump line and remove valve. g. Discard packing (21).
o. Remove 3 inch bolts and install washers (22) and bolts (21) to secure bladder cell access cover. p. Install conduit seal (14), washers (15, 16) and nut ( 17) on access cover and secure nut with MS20995C32 lockwire. (QA) q. Ins tall pins in connector 01-75PAA-2-15, WP 007 00). (NAVAIR
r. Secure electrical harness to structure with five clips and connect plug to receptacle. Secure with MS20995C20 lockwire. (QA) s. Remove tags from FUEL MANAGEMENT panel and FUEL DUMP switch. t. Remove tags and close circuit breakers.
17. TRANSFER PUMP PRESSURE CONTROL VALVE INSTALLATION.
u. Perform fuel leak check and functional check (WP 004 00). (QA) v. Close FWD FUEL PUMP ACCESS door. bomb bay doors (NAVAIR Nomenclature Lockwire Petrolatum Materials Required Specification/ Part No. MS20995C32 VV-L-236
w. Close 01-75PAA-2-2).
16. TRANSFER PUMP PRESSURE CONTROL VALVE REMOVAL.
NOTE
Power shall be disconnected from aircraft, static ground cable installed and external power switch tagged before performing fuel system maintenance. Refer to NAVAIR 01-1A-35. a. Remove power fr om air craft (NAVAIR 01-75PAA-2-1, WP 010 00). b. Verify that switches on fueling control panel are set to OFF or CLOSED and tagged and that switches on FUEL MANAGEMENT panel are set to CLOSE and tagged.
NOTE
PETROLATUM 2
007 00
Page 34
c. Lubricate packing (21, Figure 3) with petrolatum and install on pressure control valve and install valve into fitting (29) at transfer pump discharge port. (QA) d. Secure fuel pressure control valve (22) with lockwire. (QA) e. Install transfer pump. (QA) Refer to AFT TRANSFER PUMP INSTALLATION or FORWARD TRANSFER PUMP INSTALLATION this WP as applicable. f. Perform functional check (WP 004 00). (QA)
Transfer pump pressure switches are identical and are located on forward bulkhead of compartment approximately 10 inches to left of centerline near overhead pressure deck. e. Remove electrical connector from top of fuel transfer pump pressure switch (28, Figure 6). f. Disconnect and cap pressure switch (28) drain line (34) at elbow (33) and pressure line (39) at union (38) attachment. g. Remove nuts (36), washers (30, 35) and screws (29) that secure pressure switch (28) to bracket (41) and remove pressure switch. h. Remove union (38), discard packing (37) and retain union for installation. i. Loosen nut (32) at elbow (33), remove elbow and discard packing (31). Retain elbow and nut for installation. 19. PUMP PRESSURE SWITCH INSTALLATION. Materials Required Nomenclature Lockwire Petrolatum Specification/ Part No. MS20995C20 VV-L-236
18. PUMP PRESSURE SWITCH REMOVAL.
NOTE
All fuel cell maintenance shall be consistent with requirements of NAVAIR 01-1A-35. a. Verify that switches on fueling control panel are set to OFF or CLOSED and tagged. b. Verify that switches on FUEL MANAGEMENT panel are set to CLOSE and tagged. c. Open center section compartment access panel. d. Remove power from aircraft (NAVAIR 01-75PAA-2-1, WP 010 00).
Power shall be disconnected from aircraft, static ground cable installed and external power switch tagged before performing fuel system maintenance. Refer to NAVAIR 01-1A-35. a. Remove power from aircraft (NAVAIR 01-75PAA-2-1, WP 010 00).
007 00
Page 35/(36 Blank)
007006
Figure 6. Transfer Pump Pressure Switches and Dual Check Valve Removal and Installation
b. Verify that switches on fueling control panel are set to OFF or CLOSED and tagged and that switches on FUEL MANAGEMENT panel are set to CLOSE and tagged. c. Set pressure switch (28, Figure 6) in bracket (41) and secure, with screws (29), washers (30, 35) and nuts (36).
007 00
Page 37 Support Equipment Required (Cont) Nomenclature Respirator, Air Line Set, Explosive Gas Detector Spanner, Wrench Type Designation/ Part No. CAGE GGG-M-125/1B, 81348 Type II 72-8001 51906
PETROLATUM
d. Lubricate and install packing (37) and union (38) in bottom of pressure switch (28). e. Connect pressure line (39) to union (38).
NOTE
PETROLATUM
f. Lubricate packing with petrolatum and install on elbow (33) in drain flow fitting of pressure switch (28). g. Connect drain line (34) to elbow (33).
h. Install electrical connector plug at top of pressure switch (28) and lockwire. (QA) i. Remove tags from fuel transfer pump control switches on fuel management panel and FUEL DUMP switch. j. Perform functional check (WP 004 00). (QA)
Power shall be disconnected from aircraft, static ground cable installed and external power switch tagged before performing fuel system maintenance. Refer to NAVAIR 01-1A-35. b. Verify that switches on fueling control panel are set to OFF or CLOSED and tagged. c. Verify that switches on FUEL MANAGEMENT panel are set to CLOSE and tagged. d. Remove power fr om air craft (NAVAIR 01-75PAA-2-1, WP 010 00). e. Remove aft transfer pump from bladder cell. Refer to AFT TRANSFER PUMP REMOVAL this WP. f. Remove screws (18, Figure 3) securing pump support (17) in position at aft transfer pump access cover (14) and leave support loose in fuel tank until manhole is opened. g. Disengage two external line support brackets (1, 46) from manhole fitting (11).
k. Close center section compartment access panel. 20. DUAL CHECK VALVE REMOVAL. Support Equipment Required Nomenclature Mask, Hose Blower Type Designation/ Part No. CAGE AS02
h. Remove bolts (16) and washers (15) securing aft transfer pump access cover (14) and remove cover. Remove and discard seal. 21.
007 00
Page 38 DUAL CHECK VALVE INSTALLATION.
Nomenclature No person shall enter a fuel tank unless certified safe for entry by an aviation gas free engineering technician (AVGFET). Refer to NAVAIR 01-1A-35. i. Monitor atmosphere in fuel tank (WP 008 00). Mask, Hose Blower Respirator, Air Line Set, Explosive Gas Detector
j. Remove aft transfer pump s upport (17) through manhole opening. k. Open center section compartment access panel and locate main fueling line (17, Figure 6) at forward bulkhead. Remove bolts (16) and washers (15) that secure main fueling line to dual check valve (26). l. Remove bolts (18) and washers (19) that secure fueling and transfer line fitting (10) and dual check valve (26) to bladder cell and aircraft structure. Materials Required Specification/ Part No. MS20995C32 VV-L-236
Personnel performing maintenance inside fuel tanks shall wear an air-supplied respirator at all times. Fresh air shall be circulated through the fuel tank while personnel are inside. Refer to NAVAIR 01-1A-35. m. Purge fuel bladder cell (NAVAIR 01-1A-35).
Power shall be disconnected from aircraft, static ground cable installed and external power switch tagged before performing fuel system maintenance. Refer to NAVAIR 01-1A-35. a. Remove power from aircraft (NAVAIR 01-75PAA-2-1, WP 010 00). b. Verify that switches on fueling control panel are set to CLOSE and tagged and that switches on FUEL MANAGEMENT panel are set to CLOSE and tagged.
n. Remove transfer pump pressure lines (6, 27) from pressure transmitter unions (7). o. Disconnect Wiggins-Type coupling (6, Figure 3) between dual check valve and fueling and transfer valve housing (25) (WP 004 00). p. Disconnect Wiggins-Type coupling (6) from forward and aft pump discharge lines (1, 8, Figure 6). q. Remove dual check valve from fuel tank.
PETROLATUM
r. Remove unions (7) from dual check valve and retain for installation. Discard packings.
c. Lubricate packing (9, Figure 6) with petrolatum and install in groove of fueling and transfer line fitting (10).
007 00
Page 39 m. Install aft transfer pump (19) in fuel tank. Refer to AFT TRANSFER PUMP INSTALLATION this WP.
Personnel performing maintenance inside fuel tanks shall wear an air-supplied respirator at all times. Fresh air shall be circulated through the fuel tank while personnel are inside. Refer to NAVAIR 01-1A-35. No person shall enter a fuel tank unless certified safe for entry by an aviation gas free engineering technician (AVGFET). Refer to NAVAIR 01-1A-35. d. Monitor atmosphere in fuel tank (WP 008 00).
n. Secure dual check valve and fueling and transfer line fitting (10, Figure 6) to bladder cell and aircraft structure with bolts (18) and washers (19) in center section compartment. Tighten bolts. o. Install packing (9) in dual check valve groove and secure main fueling line with bolts (16) and washers (15). Tighten bolts. p. Remove tags from fueling control panel, FUEL MANAGEMENT panel and FUEL PUMP switch. q. Perform fuel leak check and functional check (WP 004 00). (QA)
PETROLATUM
2 r. Close center section compartment access panel. 22. BALL CHECK VALVE AND STANDPIPE REMOVAL.
e. Lubricate packings (21, 22) with petrolatum and connect dual check valve (26) outlet to fueling and transfer valve coupling. f. Lubricate packings (4) with petrolatum and connect forward and aft fuel transfer pump discharge lines (1, 8) to dual check valve (26) with Wiggins-Type coupling (WP 004 00). Lockwire all couplings. (QA) g. Lubricate packings (5) with petrolatum and install on unions (7). Install unions in check valve. h. Connect fuel transfer pump pressure lines (6, 27) to check valve unions (7). i. Place aft transfer pump support (17, Figure 3) in fuel tank through manhole opening.
Nomenclature Mask, Hose Blower Respirator, Air Line Set, Explosive Gas Detector Spanner, Wrench
PETROLATUM
NOTE
All fuel cell maintenance shall be consistent with requirements of NAVAIR 01-1A-35. a. Defuel No. 5 fuel tank (bladder cell and center section) (NAVAIR 01-75PAA-2-1, WP 011 00). b. At forward load center on EXTENSION MAIN DC BUS circuit breaker panel, open and tag FUEL
j. Lubricate seal with petrolatum and install on aft transfer pump access cover and install cover. Tighten bolts. k. Secure external fuel line support bracket (1, 46) on manhole fitting (11), right and left sides. l. Install transfer pump support (17) and secure with screws (18).
TRANSFER PUMP CONT FWD and AFT circuit breakers. c. At main load center, open and tag the following circuit breakers:
007 00
Page 40 i. Remove screws securing pump support in position at aft fuel transfer pump access cover. Leave support in fuel tank until manhole is opened. j. Remove two external line support brackets from manhole cover. k. Remove bolts and washers that secure manhole cover. Remove manhole cover and seal. Discard seal.
Name FUEL DUMP CONT FUEL DUMP VALVE TRANSFER PUMP FWD FUEL BABBBC AFT FUEL TRANS PUMP BABBBC FUEL DUMP PUMP
Location MAIN DC BUS circuit breaker panel MAIN DC BUS circuit breaker panel MAIN AC BUS A forward circuit breaker panel MAIN AC BUS B forward circuit breaker panel MAIN AC BUS A aft circuit breaker panel
No person shall enter a fuel tank unless certified safe for entry by an aviation gas free engineering technician (AVGFET). Refer to NAVAIR 01-1A-35. l. Monitor atmosphere in fuel tank (WP 008 00).
m. Remove aft fuel transfer pump support through manhole opening. n. Open center section compartment access panel and locate fueling interconnect hose on the forward bulkhead. Remove fueling interconnect hose from ball check valve fitting.
Power stall be disconnected from aircraft, static ground cable installed and external power switch tagged before performing fuel system maintenance. Refer to NAVAIR 01-1A-35. d. Verify that switches on fueling control panel are set to OFF or CLOSED and tagged. e. Verify that switches on FUEL MANAGEMENT panel are set to CLOSE and tagged. f. Verity that FUEL DUMP switch is set to OFF and tagged. g. Remove power from aircraft (NAVAIR 01-75PAA-2-1, WP 010 00). h. Remove aft fuel transfer pump from bladder cell. Refer to AFT TRANSFER PUMP REMOVAL this WP.
Personnel performing maintenance inside fuel tanks shall wear an air-supplied respirator at all times. Fresh air shall be circulated through the fuel tank at all times while personnel are inside. Refer to NAVAIR 01-1A-35. o. Purge fuel bladder cell (NAVAIR 01-1A-35).
p. Remove bolts securing valve to overflow fitting at fuel tank rear wall (Figure 7). q. Remove lockwire from Wiggins-Type coupling at standpipe to overflow fitting, disassemble coupling and remove standpipe (WP 004 00).
007 00
Page 41
Figure 7.
Ball Check Valve and Standpipe Removal and Installation
007007
r. Remove screws, washers and nuts that secure standpipe clamps at top of standpipe to bracket. s. Remove bolts that secure overflow fitting and fuel tank interconnect fitting to bladder cell and aircraft structure. Remove overflow fitting. 23. BALL CHECK VALVE AND STANDPIPE INSTALLATION.
007 00
Page 42
Personnel performing maintenance inside fuel tanks shall wear an air-supplied respirator at all times. Fresh air shall be circulated through the fuel tank while personnel are inside. Refer to NAVAIR 01-1A-35. No person shall enter a fuel tank unless certified safe for entry by an aviation gas free engineering technician (AVGFET). Refer to NAVAIR 01-1A-35. d. Monitor atmosphere in fuel tank (WP 008 00).
Support Equipment Required Nomenclature Mask, Hose Blower Respirator, Air Line Set, Explosive Gas Detector Spanner, Wrench Type Designation/ Part No. CAGE AS02 GGG-M-125/1B, 81348 Type II 72-8001 51906
PETROLATUM Materials Required Nomenclature Lockwire Petrolatum Specification/ Part No. MS20995C32 VV-L-236
e. Lubricate with petrolatum and install packing in overflow fitting groove (Figure 7). Secure overflow fitting to fuel tank fitting interconnect fitting, bladder cell and aircraft structure with bolts and washers. Tighten bolts. f. Lubricate with petrolatum and install packing on interconnecting hose. Install hose to overflow fitting with bolts and washers. Tighten bolts. g. Lubricate packings with petrolatum. Position lower end of standpipe to overflow fitting. Install Wiggins-Type coupling with packings (WP 004 00). Do not tighten coupling at this time. h. Install upper end of standpipe and bonding jumper to bracket on fueling transfer valve with clamps, screws, washers and nuts. Tighten WigginsType coupling and lockwire. (QA) i. Install ball check valve and gasket on overflow fitting with bolts, washers and nuts. Tighten bolts. j. tank. Place aft fuel transfer pump support in fuel
Power shall be disconnected from aircraft, static ground cable installed and external power switch tagged before performing fuel system maintenance. Refer to NAVAIR 01-1A-35. a. Verify power is removed from aircraft (NAVAIR 01-75PAA-2-1, WP 010 00). b. Verify that switches on fueling control panel are set to OFF or CLOSED and tagged and that switches on FUEL MANAGEMENT panel are set to CLOSE and tagged. c. Verify FUEL DUMP switch is set to OFF and tagged.
007 00
Page 43 e. At main load center, open and tag the following circuit breakers:
PETROLATUM
2 Name Location MAIN DC BUS circuit breaker panel MAIN DC BUS circuit breaker panel MAIN AC BUS A forward circuit breaker panel MAIN AC BUS B forward circuit breaker panel MAIN AC BUS A aft circuit breaker panel
k. Lubricate with petrolatum and install seal on manhole cover. Install cover and torque bolts to proper torque value. (QA) l. Install fuel line support bracket to manhole cover. m. Position fuel transfer pump in fuel tank.
FUEL DUMP CONT FUEL DUMP VALVE TRANSFER PUMP FWD FUEL BABBBC AFT FUEL TRANS PUMP BABBBC FUEL DUMP PUMP
n. Install aft fuel transfer pump in fuel tank. Refer to AFT TRANSFER PUMP INSTALLATION this WP. o. Remove tags from fueling control panel, fuel management panel and FUEL DUMP switch. p. Remove tags and close FUEL TRANSFER PUMP CONT, FUEL DUMP CONT, FUEL DUMP VALVE, AFT FUEL TRANSFER PUMP and FUEL DUMP circuit breakers. q. Perform fuel leak check and functional check (WP 004 00). (QA) 24. AFT TRANSFER PUMP ELECTRICAL CONDUIT AND OVERBOARD DRAIN REMOVAL.
f. Defuel No. 5 fuel tank (bladder cell and center section) (NAVAIR 01-75PAA-2-1, WP 011 00). g. Open center section compartment access panel.
NOTE
All fuel cell maintenance shall be consistent with requirements of NAVAIR 01-1A-35. a. Verify that switches on fueling control panel are set to OFF or CLOSED and tagged. b. Verify that switches on FUEL MANAGEMENT panel are set to CLOSE and tagged. c. Verify FUEL DUMP switch is set to OFF and tagged. d. At forward load center on EXTENSION MAIN DC BUS circuit breaker panel, open and tag FUEL TRANSFER PUMP CONT FWD and AFT circuit breakers.
Power shall be disconnected from aircraft, static ground cable installed and external power switch tagged before performing fuel system maintenance. Refer to NAVAIR 01-1A-35. h. Remove power fr om air craft (NAVAIR 01-75PAA-2-1, WP 010 00). i. Disconnect aft transfer pump electrical connector and remove pins from electrical connector (NAVAIR 01-75PAA-2-15, WP 007 00). j. Remove nut, washers and seal from aft transfer pump electrical conduit and overboard drain fitting and remove from wiring harness (Figure 8). k. Disconnect drain line at union in aft fuel transfer pump electrical conduit and drain fitting. Remove union.
007 00
Page 44
Figure 8.
Aft Transfer Pump Electrical Conduit Overboard Drain Removal and Installation
007008
l. Remove drain line from bracket at lower fuselage skin and lift line from grommet. m. Remove bolts and washers from conduit and drain fitting. n. Remove aft transfer pump electrical conduit and overboard drain fitting from aft fuel transfer pump wiring harness. o. Discard grommet, packing, seal and gaskets.
007 00
Page 45 c. Thread aft transfer pump wiring harness through gaskets, aft transfer pump electrical conduit and overboard drain fitting, seal, washers and nut (Figure 8). d. Secure aft transfer pump electrical conduit and overboard drain fitting with washers and bolts. e. Insert seal and washers into aft transfer pump electrical conduit and overboard drain fitting tighten nut.
25. AFT TRANSFER PUMP ELECTRICAL CONDUIT AND OVERBOARD DRAIN INSTALLATION.
Support Equipment Required Nomenclature Type Designation/ Part No. CAGE 81348 81348 COMPOUND, SEALING, POLYSULFIDE 4
f. Apply coat of sealing compound around periphery of gaskets and aft transfer pump electrical conduit and overboard drain fitting. g. Install grommet in fuselage skin and insert drain line through grommet. h. Secure drain line to bracket with clamp, screw, washer and nut.
Compound, Sealing, Polysulfide, MIL-S-8802, Type II for Brush Application Petrolatum VV-L-236
PETROLATUM Power shall be disconnected from aircraft, static ground cable installed and external power switch tagged before performing fuel system maintenance. Refer to NAVAIR 01-1A-35. a. Verify power is removed from aircraft (NAVAIR 01-75PAA-2-1, WP 010 00). b. Verify that switches on fueling control panel are set to OFF or CLOSED and tagged and that switches on FUEL MANAGEMENT panel are set to CLOSE and tagged.
i. Lubricate packing with petrolatum and install packing on union. j. Install union with packing in aft transfer pump electrical conduit and overboard drain fitting and connect drain line. k. Assemble aft transfer pump electrical connector (NAVAIR 01-75PAA-2-15, WP 007 00).
l. Secure electrical wire bundle and connect electrical connector at bracket. m. Remove tags and close circuit breakers.
007 00
Page 46
n. Remove tags from switches on fueling control panel, fuel management panel and FUEL DUMP switch. o. p. Perform fuel leak check (WP 004 00). (QA) Close center section access panel.
TURBINE FUEL, AVIATION d.
Drain residual fuel into safety fuel container.
e. Remove four bolts (3, Figure 9) and washers (4) securing drain valve (2). f. Remove drain valve (2). Remove and discard packing (1). 27. FUEL (BLADDER) CELL DRAIN VALVE REPAIR.
26. FUEL (BLADDER) CELL DRAIN VALVE REMOVAL. Support Equipment Required Nomenclature Container, Safety, Fuel, 5 gal Gauge, Force, 0 to 25 lb-ins Type Designation/ Part No. CAGE
Support Equipment Required Type Designation/ Part No. CAGE MIL-C-14610 ZZ-G-381 GG-G-531 GG-M-125/6 81349 81348 81348 81348
Nomenclature Coveralls Gauge, Force, 0 to 25 lb-ins Gloves, Rubber, Industrial Goggles, Industrial and Spectacles Respirator, Cartridge Organic Vapor
NOTE
All fuel cell maintenance shall be consistent with requirements of NAVAIR 01-1A-35. a. Defuel No. 5 fuel tank (bladder cell and center section) (NAVAIR 01-75PAA-2-1, WP 011 00). b. Verify that switches on FUEL MANAGEMENT panel are set to CLOSE and tagged.
Materials Required Specification/ Part No. P-D-680, Type III or II (Type III preferred) MS20995C32 VV-L-236
Nomenclature Power shall be disconnected from aircraft, static ground cable installed and external power switch tagged before performing fuel system maintenance. Refer to NAVAIR 01-1A-35. c. Remov e power from aircraft (NAVAIR 01-75PAA-2-1, WP 010 00). Brush, Bristle Cloth, Lint-free Solvent, Dry Cleaning Lockwire Petrolatum
007 00
Page 47
Figure 9.
Fuel (Bladder) Cell Drain Valve Removal and Installation
007009
a. lows: Disassemble drain valve (2, Figure 9) as fol-
007 00
Page 48 g. Inspect threaded parts on spring retainer (5) and body (10) for damage to threads. (QA) h. Replace damaged parts unless minor repair will restore serviceability. i. Replace any damaged part which affects sealing or operating action. j. Replace spring (6) if visually damaged or if force required to open poppet (7) is not within 103.0 pounds. Refer to paragraph 27k(9) for procedures to force test poppet valve. k. Assemble drain valve (2) as follows:
Care shall be exercised when removing spring retainer, to prevent injury to personnel. (1) Position drain valve (2) in holding de-
vice.
(2) Cut lockwire (15) and remove spring retainer (5). (3) Remove spring (6) and poppet (7).
(4) Remove screws (13) securing seal retainer (12) to drain valve body (10). (5) Discard all packings (8, 9, 11).
PETROLATUM
(1) Lubricate packing (11) with petrolatum and install on seal retainer (12). (2) Attach packing (11) and retainer (12) to drain valve body with screws (13).
5 PETROLATUM 2
(3) Lubricate packings (8, 9) with petrolatum and install on poppet (7). SOLVENT, DRY CLEANING, TYPE II 6 (4) Coat entire poppet (7) lightly with petrolatum and insert in drain valve body (10). (5) Lubricate spring (6) with petrolatum and position on top of poppet (7) inside drain valve body (10). (6) Position spring retainer (5) over end of spring (6). (7) Apply downward pressure to spring retainer (5) compressing spring (6) and threading spring retainer into drain valve body (10). (8) Tighten retainer (5) and lockwire (15).
b. Use brush to clean all metal parts in dry cleaning solvent. c. cloth. d. (QA) Thoroughly dry all parts with clean lint-free
Inspect all parts for damage and corrosion.
e. Inspect valve body and poppet (7) for areas of concentrated wear and scoring. (QA) f. Inspect valve seal retainer (12) areas and spring (6) for damage or distortion. (QA)
(QA)
RAC 9 - 19 June 1997 (9) Check valve section by manually pressing poppet (7). Action should be smooth and require a force of 103.0 pounds to open. 28. FUEL (BLADDER) CELL DRAIN VALVE INSTALLATION.
007 00
Page 49 f. Check valve action by pressing poppet (7). Action should be smooth and require a force of 103.0 pounds to open. g. Remove tags from flight station FUEL MANAGEMENT panel and external power switch. h. Perform fuel leak check (WP 004 00). (QA) Close drain valve access panel. (QA)
i.
29. FUEL (BLADDER) CELL DRAIN MAST REMOVAL.
Do not strike or bump the mast with any object. Power shall be disconnected from aircraft, static ground cable installed and external power switch tagged before performing fuel system maintenance. Refer to NAVAIR 01-1A-35. a. Verify power is removed from aircraft (NAVAIR 01-75PAA-2-1, WP 010 00). b. Verify that switches on FUEL MANAGEMENT panel are set to CLOSE and tagged. Do not strike or bump the mast with any object. PETROLATUM 2 a. Unfasten fastener studs (23, Figure 10) on left side of mast flange. b. c. Remove hinge pin (25) from hinge assembly. Remove mast from aircraft.
30. FUEL (BLADDER) CELL DRAIN MAST INSTALLATION.
NOTE
Hinge assemblies are a matched set. Do not replace one hinge half without replacing the other. This will ensure adequate security of the mast assembly to the aircraft. a. Position and align drain mast and mast pad hinge halves and install hinge pin (25) into hinge assembly.
c. Lubricate packing (1, Figure 9) with petrolatum and position on drain valve (2). (QA) d. Insert drain valve (2) in fuel tank opening.
e. Secure drain valve (2) in position with bolts (3) and washers (4).
007 00
Page 50
Figure 10.
Fuel (Bladder) Cell Drain Mast (Sheet 1 of 2)
00701001
007 00
Page 51
00701002
Figure 10.
Fuel (Bladder) Cell Drain Mast (Sheet 2)
RAC 9 - 19 June 1997
007 00
Page 52
NOTE
When installing fastener studs on mast, verify the correct fastener stud lengths are used. This ensures that the mast is adequately secured to the aircraft. b. Position mast such that it is in a vertical position and install fastener studs (23, figure 10) on mast. c. Secure fastener studs and verify security of mast to the aircraft. 31. FUEL (BLADDER) CELL DRAIN MAST INSPECTION. Do not stress the mast radius, hinge pin or the pad on the aircraft. (2) Gently push mast lower end to left side until looseness in hinge is removed. Take care not to stress mast radius (4), hinge pin (25) or pad (19) on aircraft. (3) Using feeler gauge, measure gap between top of hinge lobes on hinge half (24) and lower fuselage surface. Replace mast if gap is greater than 0.020 inch.
NOTE
Hinge assemblies are a matched set. Do not replace one hinge half without replacing the other. This will ensure adequate security of the mast assembly to the aircraft. (4) Inspect hinge lobes for cracks. If one hinge lobe is cracked or broken off and adjacent lobe in same hinge half is cracked, replace affected hinge half. b. Inspect external surface of mast for cracks. Pay particular attention to vertical portion of the mast and lower mast base surface (especially around fastener stud holes) and along forward and aft mast seams along entire length. Inspect mast as follows:
Nomenclature Gauge, Feeler
Nomenclature
Cloth, Aluminum Oxide Abrasive P-C-451, Grit 180
Do not stress the mast radius. Do not strike or bump the mast with any object. a. Inspect mast hinge assembly as follows: (1) With mast down and locked, grasp mast lower end and gently push mast to left side until looseness in hinge is removed. Take care not to stress mast radius (4). (2) Visually inspect mast right side, leading and trailing edge seams (5, 9) for cracks. Mark ends of cracks with grease pencil. Release side pressure.
(1) Verify mast is down and secured to aircraft and hinge pin (25, Figure 10) is fully installed.
RAC 9 - 19 June 1997 (3) Repeat steps (1) and (2), gently pushing mast to right side and inspecting left side for cracks. (4) If cracks are detected, proceed to step
007 00
Page 53/(54 Blank) (c) Verify cracks exceed negligible damage limits (NAVAIR 01-75PAA-3-1). (d) If cracks exceed negligible damage limits, repair mast (NAVAIR 01-75PAA-3-1). (e) If cracks do not exceed negligible damage limits, touch up paint on mast (NAVAIR 01-75PAA-2-2.1 and NAVAIR 01-1A-509). (5) Install mast on aircraft. Refer to FUEL (BLADDER) CELL DRAIN MAST INSTALLATION this WP.
(a).
(a) Remove mast from aircraft. Refer to FUEL (BLADDER) CELL DRAIN MAST REMOVAL this WP. (b) Remove paint over area in question using abrasive cloth.
008 00
Page 1
ORGANIZATIONAL MAINTENANCE CONFINED SPACE (FUEL TANK) TESTING AIRCRAFT FUEL SYSTEM
Reference Material Aircraft Fuel Cells and Tanks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . NAVAIR 01-1A-35 Explosive Gas Detector Set, PN 72-8001 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . NAVAIR 17-75-63 Alphabetical Index Subject Confined Space (Fuel Tank) Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Testing Fuel Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Monitoring Fuel Tank Atmosphere . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Procedures Covered In Other Manuals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Record of Applicable Technical Directives None 1. PROCEDURES COVERED IN OTHER MANUALS. 2. Fuel system maintenance safety procedures are covered in NAVAIR 01-1A-35. technician (AVGFET) using explosive gas detector set, part number 72-8001, or equivalent. 6. Testing is performed progressively, first from outside of fuel tank (initial testing) and then from inside of fuel tank (internal testing). Test for oxygen content is always conducted first followed by vapor test. Once initial and internal testing indicate acceptable levels of oxygen and combustible gases, an internal fuel tank inspection is performed for flammable residues and materials. After completion of testing and any actions required to ensure safe conditions within fuel tank, a Navy aviation gas free certificate is issued by an AVGFET. Continuous or periodic monitoring of fuel tank atmosphere is performed using an explosive gas detector whenever maintenance is being accomplished within fuel tank. Page No. 1 1 2 3 1
NOTE
NAVAIR 01-1A-35 shall be used in conjunction with and in support of fuel system maintenance procedures contained in this manual. However, if there is a conflict between NAVAIR 01-1A-35 and the maintenance procedures contained in this manual, NAVAIR 01-1A-35 shall take precedence. 3. Operation of explosive gas detector set, part number 72-8001, is covered in NAVAIR 17-75-63. 4. CONFINED SPACE (FUEL TANK) TESTING. 5. DESCRIPTION. Testing of a confined space (fuel tank) for safe entry is comprised of an oxygen and vapor test to determine oxygen content and to detect presence of combustible gases within fuel tank. Testing is conducted by an aviation gas free engineering
No person shall enter a fuel tank/cell unless certified safe for entry by an AVGFET.
Change 1 - 1 October 1995 7. When hazardous conditions are detected within fuel tank all work shall be stopped immediately and personnel shall be removed from fuel tank. Entry or work shall not be resumed until all unsafe conditions have been corrected or controlled, and the space has been retested and recertified.
008 00
Page 2
NOTE
When entry into a fuel tank is necessary to remove hazardous concentrations of flammables and/or to conduct testing, inspections, evaluations, etc., the following restrictions apply: personnel entering fuel tank must be equipped with approved air-supplied respirators, protective clothing, and explosion-proof or safe equipment. Safety observer with assistant must be stationed outside fuel tank. Communication between personnel inside and outside fuel tank must be established and maintained (NAVAIR 01-1A-35). Initial testing is performed from outside of fuel tank by drop tests or insertion of explosive gas detector sample probe and hose into space. When hazardous concentrations of combustible gases or deviations from normal oxygen levels are indicated, the fuel tank shall be ventilated and/or cleaned. a. Initial Test.
NOTE
Use explosive gas detector set, part number 72-8001, or equivalent. Refer to NAVAIR 17-75-63 for operating instructions. Only an AVGFET or gas free engineer (GFE) is authorized to use the explosive gas detector set to test samples of atmosphere. 8. Oxygen content of fuel tank atmosphere should be 20 to 22 percent. Levels of combustible gases must be at or below 10 percent of the lower explosion limit (LEL), however, due to many variables involved with testing instruments and the frequent inability to obtain finite readings, any reading observed on the explosive gas detector in the LEL range should be considered as an unsafe condition (NAVAIR 01-1A-35). 9. TESTING FUEL TANK.
Support Equipment Required Type Designation/ Part No. CAGE MIL-C-14610 ZZ-G-381 GG-G-531 MIL-F-16377/52 57A42 AS02 NF15-3 GGG-M-125/1B Type II 72-8001 81349 81348 81348 81348 51906
(1) Ensure ventilation to fuel tank being tested is off. (2) Insert explosive gas detector sample probe into space being tested. (3) (4) Perform oxygen test. Perform vapor test.
Nomenclature Coveralls Gloves, Rubber, Industrial Goggles, Industrial and Spectacles Light, Extension, Explosion-proof Light, Fuel Cell Inspection Mask, Hose Blower Pump, Breathing, Ambient Air Respirator Air Line Set, Explosive Gas Detector
When internal testing of fuel tank indicates presence of hazardous concentrations of combustible gases or deviations from normal oxygen levels the tester shall exit tank and the space shall be ventilated and/or cleaned.
NOTE
Internal testing is performed only after initial testing indicates that oxygen content and combustible gases within fuel tank are at acceptable levels. b. Internal Test.
008 00
Page 3/(4 Blank) valid for the period specified by the AVGFET. Space shall be continuously or periodically monitored as necessary and certificate updated to maintain safe conditions within fuel tank. d. Issue Navy aviation gas free certificate (NAVAIR 01-1A-35). 10. MONITORING FUEL TANK ATMOSPHERE.
(1) Enter fuel tank with explosive gas detector sample probe tube extended into space being tested. (2) (3) (4) Perform oxygen test. Perform vapor test. Restore ventilation to fuel tank.
NOTE
Internal inspection of fuel tank is performed only after internal testing determines that oxygen content and combustible gases within fuel tank are at acceptable levels. c. Internal Inspection.
Fuel tank atmosphere must be continuously or periodically monitored as necessary to maintain safe conditions within fuel tank whenever personnel are performing internal fuel tank maintenance. If explosive gas detector gives a lower explosion limit alarm (LEL) personnel must leave area immediately. b. Approach area where maintenance is being performed with explosive gas detector sample probe extended. If explosive gas detector gives a LEL alarm, immediately withdraw all personnel from area and take appropriate action to purge area of dangerous fumes (NAVAIR 01-1A-35). c. Monitor explosive gas detector while maintenance is being performed in or around fuel tank. d. After completion of maintenance and after personnel have left area, turn off power and secure explosive gas detector.
(1) Inspect internal fuel tank for presence of flammable or combustible residues, blisters or scale which may trap hazardous substances, rags, rope, wood, and other materials.
NOTE
Upon completion of testing, inspection, evaluation, space cleaning, and/or ventilation as appropriate, a Navy aviation gas free certificate shall be issued. Certificates issued for entry or work in or around fuel tank shall be
009 00
Page 1
ORGANIZATIONAL MAINTENANCE EXPLOSION SUPPRESSANT FOAM BAFFLE SYSTEM MAINTENANCE AIRCRAFT FUEL SYSTEM
Reference Material System Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 004 00 Fuselage Fuel (Bladder) Cell Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 007 00 Confined Space (Fuel Tank) Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 008 00 Aircraft Fuel Cells and Tanks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . NAVAIR 01-1A-35 General Information and Servicing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . NAVAIR 01-75PAA-2-1 Line Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 010 00 Fueling System Servicing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 011 00 Powerplant and Related Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . NAVAIR 01-75PAA-2-4 Ground Runup Operational Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 010 00 Powerplant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . NAVAIR 01-75PAA-2-4.3 Engine Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 010 00 Auxiliary Power Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . NAVAIR 01-75PAA-2-4.4 Fuel Control System Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 010 00 Powerplant Related Electrical Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . NAVAIR 01-75PAC-2-13.1.2 Aircraft Refueling for Shore Activities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . NAVAIR 06-5-502 Alphabetical Index Subject Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Foam Baffle Drying Container Fabrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Foam Baffle Fabrication and Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Foam Baffle Inspection Criteria . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Foam Baffle Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Foam Baffle Removal and Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fuel System Ground Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Procedures Covered in Other Manuals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Record of Applicable Technical Directives Type/No. AFC 517 Date Title and ECP No. P--3B and P--3C Explosion Suppressant Foam (ESF) Installation In Aircraft Fuel Tanks Date Inc. Remarks Page No. 2 3 2 3 14 4 31 1
1. PROCEDURES COVERED IN OTHER MANUALS.
NOTE
NAVAIR 01-1A-35 shall be used in conjunction with and in support of fuel system maintenance procedures contained in this manual. However, if there is a conflict between NAVAIR 01-1A-35 and the maintenance procedures contained in this manual, NAVAIR 01-1A-35 shall take precedence.
2. Aircraft fueling and defueling precautions and procedures are covered in NAVAIR 01-75PAA-2-1. Fuel system maintenance safety procedures are covered in NAVAIR 06-5-502 and NAVAIR 01-1A-35. Digital Fuel Quantity System maintenance procedures are covered in NAVAIR 01-75PAC-2-13.1.2.
Change 2 - 1 July 1998 3. MAINTENANCE. 4. FOAM BAFFLE IDENTIFICATION. FABRICATION AND
009 00
Page 2 surface over a 1/4 inch mesh screen to dislodge trapped foam particles after cutting. The use of cotton gloves shall be avoided because they can contaminate the foam baffles with lint. Rubber gloves shall be worn for removal, handling and installation of the foam baffles. The foam baffles shall not be left in direct sunlight for longer than 30 minutes. The ultraviolet (UV) component of sunlight may cause deterioration on the surface of the foam baffles. a. Fabricate foam baffle in a clean, dry and relatively dust-free area. Lay out and cut foam baffle on a smooth hard surface work bench. Rotate and bounce each surface of newly cut foam baffle on a frame covered with 1/4 inch mesh screen.
Support Equipment Required Type Designation/ Part No. CAGE ZZ-G-381 GGG-C-746 Blairdell 1173F 81348 81348
Nomenclature Gloves, Rubber, Industrial Knife, Foam Marker, Fuel Resistant Screen, Mesh, 1/4 in
Materials Required
NOTE
Nomenclature Foam, Explosion Suppressant (Foam Baffle) Specification/ Part No. MIL-F-87260B, Class 2, Grade IC The color of the fuel resistant marker should be chosen to contrast with the color of the foam baffles. The identifying number letter combination indicates the fuel tank, fuel tank subsections, installation and removal sequence and location in the fuel tank relative to other baffles. Electric or hot wire cutters shall not be used on previously installed (wet) foam baffles nor in the immediate fuel tank repair area. The foam baffles may be dry to the touch but still contain fuel which may ignite. Debris and foreign material contamination left on individual foam baffles can accumulate in fuel system filters and strainers and decrease engine performance. For example, 1-1-A-U-AFT indicates No. 1 fuel tank, cavity 1, installation part A, upper piece, facing aft. The first character denotes the fuel tank number. It is either 1, 2, 3, 4, 5 or 5A. The second character denotes the fuel tank cavity or row identification. For No. 1 through No. 4 fuel tanks, the sequence begins inboard and works outboard. For No. 5 fuel tank, the sequence begins at the right side. The sequence for No. 5A fuel tank begins at the forward bulkhead and works aft. The third character denotes the installation sequence. This shows the position of the component from forward to aft. The fourth character denotes position location (upper, lower or middle). Not all components have this marking. The last portion of the marking is the baffle facing instruction. This tells the installer which direction the marked surface of the baffle must face.
Do not cut foam baffles inside the fuel tank. Small particles may fall inside the fuel tank. Small particles of foam may remain in the foam baffles when they are cut. Each foam baffle shall be rotated and bounced on each
RAC 7 - 27 February 1997 b. Identify each foam baffle by a number letter combination marked by a fuel resistant marker on the last side exposed to view during installation or the first side exposed to view during removal. Refer to Figure 1 and FOAM BAFFLE INSTALLATION this WP. 5. FOAM BAFFLE INSPECTION CRITERIA.
009 00
Page 3 pattern or areas of stickiness. Replace burned or singed foam baffles. d. Examine foam baffles for deterioration. Use fingers to attempt to pull or tear a few strands of foam baffle at various points and compare to foam baffle material of known acceptability. If foam baffle strands tear easily or visual inspection reveals evidence of loose particles of foam strands in the open network, then foam baffle material is deteriorated. Replace deteriorated foam baffles. To t a l v o l u m e o f f o a m b a f f l e m a t e r i a l i s approximately 900 cubic feet. If more than 5 percent of total volume is found to be deteriorated, remove and replace all foam baffle material in aircraft. e. Examine foam baffles for tears and punctures. Replace foam baffle material that is excessively torn or punctured. 6. FOAM BAFFLE FABRICATION. DRYING CONTAINER
Do not wash or flush foam with water or emulsion cleaners to remove residual fuel. a. Examine foam baffles for presence of legible identification markings. Mark foam baffles which do not have legible markings using a fuel r e s i s t a n t m a r k e r. R e f e r t o F O A M B A F F L E FABRICATION AND IDENTIFICATION this WP.
Support Equipment Required Debris and foreign material contamination left on individual foam baffles can accumulate in fuel system filters and strainers and decrease engine performance. b. Examine foam baffles for foreign particles, such as collected lint fibers or other contamination. Foreign particles are especially found in lower areas of fuel tanks. Replace excessively contaminated foam which cannot be cleaned. Type Designation/ Part No. CAGE AF-17-8 NF-14-2
Nomenclature Blower Fan, 12 in
Materials Required Specification/ Part No. 2024T3
NOTE
Discoloration of the foam baffles is not a cause for rejection. Normal aging and exposure to fuel cause the foam baffles to darken in color. b . E x a m i n e f o a m b a ff l e s f o r b u r n i n g o r singeing. The most likely areas for burned or singed foam baffles are around fuel tank vent outlets and inlets. Burned or singed foam has surface color changes, rough bead-like surface formations similar to melted nylon, excessive gouging into foam
Nomenclature Sheet Metal, Aluminum, 0.032 or 0.040 in J-Slot Ring, 8 in Steel Angle, 1 in Steel Square Tube, 1 in x 10 ft Extrusions, Aluminum L-Channel Grid, Expansion Metal
009 00
Page 4
The bottom of the drying container shall contain a screened opening to allow residual fuel to drain. The drying container shall consist of screened openings at opposite ends of the longest dimension.
NOTE
An aluminum drying container should be locally manufactured. The drying container has the capacity to dry the amount of one-half to one full fuel tank of foam baffles. a. Fabricate foam baffle drying container (Figure 2). b. Mount blower with 1/4 inch mesh screen to one end of drying container. c. For more effective dual ventilation, mount fan to the other opening. 7. FOAM BAFFLE REMOVAL AND STORAGE.
Aircraft equipped with AFC-517 shall not be fueled with a portion of the foam baffle system removed or missing from any fuel tank. Incomplete baffle system in fuel tank creates voids within the foam baffle system. Foam baffles build up and retain electrostatic charge during fueling/defueling operation. This can result in electrostatic discharging between foam baffles adjacent to a void. Electrostatic discharge (arcing) in presence of fuel vapors may result in explosion.
Support Equipment Required Type Designation/ Part No. CAGE ZZ-G-381 GG-G-531 81348 81348
Aircraft equipped with AFC-517 may be fueled and flown, for functional check flight purposes only, with entire foam baffle system removed from No. 1 through No. 5A fuel tanks OR with entire foam baffle system removed from No. 1 through No. 5 fuel tanks and entire foam baffle system installed in No. 5A (bladder cell) fuel tank. Foam baffle system left in No. 5A fuel tank only, typically applies to Phased Depot Maintenance (PDM) functional check flight configuration.
Nomenclature Container, Drying Gloves, Rubber, Industrial Goggles, Industrial and Spectacles Mask, Hose Blower Respirator, Air Line Set, Explosive Gas Detector
Aircraft equipped with AFC-517 shall not be flown unless complete foam baffle system is installed in all fuel tanks. The only exception is as noted above for functional check flight.
AS02 GGG-M-125/1B, 81348 Type II 72-8001 51906
NOTE
The fuel sumps may need to be drained once each day for 4 or 5 days as residual fuel settles slowly. Some residual fuel remains in fuel tanks, as it is not possible to completely drain fuel tanks equipped with foam baffles.
Nomenclature
Bag, Opaque Antistatic Plastic MIL-B-81705, Type II Box, Corrugated MIL-B-38721 Compound, Sealing, Polysulfide, MIL-S-8802, Type II for Brush Application Petrolatum VV-L-236 Tape PPT-T-60
a. Defuel applicable fuel tank or fuel tanks (NAVAIR 01-75PAA-2-1, WP 011 00, and NAVAIR 01-1A-35).
b. On fueling control panel, set all switches to OFF or CLOSED and tag.
RAC 7 - 27 February 1997 c. On FUEL MANAGEMENT panel, set all switches to OFF or CLOSE and tag.
009 00
Page 4A/(4B blank) (1) Verify that FUEL DUMP switch is set to OFF and tagged. (2) At forward load center on MONITORABLE ESSENTIAL AC BUS circuit breaker panel, open and tag FUEL QUANTITY INDICATORS TANK 5 A circuit breaker and FUEL TRANSFER PUMP CONT FWD and AFT circuit breakers on EXTENSION MAIN DC BUS circuit breaker panel. (3) At main load center, open and tag the following circuit breakers:
NOTE
The removal of foam baffles in the No. 5 and No. 5A, fuel tanks requires an additional switch to be set to OFF and circuit breakers to be opened. d. For removal of foam baffles from No. 5 and No. 5A fuel tanks, perform the following steps:
009 00
Page 5/(6 Blank)
G F E D C B A H I
TYPICAL SET OF FOAM BAFFLES FABRICATED FOR NO. 4 FUEL TANK CAVITY 1
7 3/4
3 1/4
16 3/4
17 1/2 16 17 3/4 1 1/2 9 1/2 5 1/4 9 8 3/4 17 1/2
1-1-A-U AFT
NOTE
TYPICAL FOAM BAFFLE MARKINGS ALL DIMENSIONS ARE IN INCHES.
17 3/4
1-1-A-L AFT
Figure 1. Foam Baffle Fabrication and Markings
009 00
Page 7/(8 Blank)
15
2 60 2 30 15 1 2 1 42
2 2 1
30 2 2 1 1 2
2 72 60 2 120 1
NOTE
1 INCH ANGLE ROD FOR OUTSIDE FRAME. 1 INCH SQUARE ROD FOR INSIDE FRAME TOP, CENTER, BOTTOM AND SIDES. ALL DIMENSIONS ARE IN INCHES.
Figure 2. Foam Baffle Drying Container Fabrication (Sheet 1 of 2)
009 00
Page 9/(10 Blank)
45 8
30 BOTTOM 72
54
FRONT BACK 30 60 30 120 1 INCH ALUMINUM ANGLE 8 INCH J-SLOT RING HINGE STRIP SANDWICHED BETWEEN DOOR AND PLATE HINGE BETWEEN ALUMINUM SHEET AND FRAME OF STORAGE BOX 5 1/2
SIDE 9
12 1/4
INSIDE BACK
ALUMINUM L-CHANNEL EXTRUSIONS FOR DOOR STIFFENER
1 1/8
RUBBER TUBING
Figure 2. Foam Baffle Drying Container Fabrication (Sheet 2)
RAC 7 - 27 February 1997 Name TRANSFER PUMP FWD FUEL ABC AFT FUEL TRANS PUMP ABC FUEL INLET VALVE CONT TANK NO. 5 Location MAIN AC BUS A forward circuit breaker panel MAIN AC BUS B forward circuit breaker panel MAIN DC BUS circuit breaker panel
009 00
Page 11 g. For No. 1 through No. 4 fuel tanks, open applicable INBD or OUTBD FUEL TANK ACCESS panel (W108-L or -R or W111-L or -R). h. For No. 5 and No. 5A fuel tanks, perform aft transfer pump removal (WP 007 00) and remove manhole cover.
Personnel performing maintenance inside fuel tanks shall wear an air-supplied respirator at all times. Fresh air shall be circulated through the fuel tank while personnel are inside. Refer to NAVAIR 01-1A-35. Power shall be disconnected from aircraft, static ground cable installed and external power switch shall be set to OFF and tagged before performing fuel system maintenance. No person shall enter a fuel tank unless certified safe for entry by an aviation gas free engineering technician (AVGFET). Refer to NAVAIR 01-1A-35.
e. Remove power from aircraft (NAVAIR 01-75PAA-2-1, WP 010 00). Verify static ground cable is installed and external power switch is set to OFF and tagged (NAVAIR 01-1A-35). The use of cotton gloves shall be avoided because they can contaminate the foam baffles with lint. Rubber gloves shall be worn for removal, handling and installation of the foam baffles. Explosion suppressant foam builds up and retains electrostatic charges during fueling and defueling operations. The dissipation rate of the electrostatic charge is temperature dependent. To allow for electrostatic charge dissipation, aircraft shall remain undisturbed for a minimum of 15 minutes prior to performing aircraft fuel system maintenance. Aircraft fuel system maintenance shall not be performed during this time period. Aircraft fuel system maintenance shall not be performed when aircraft is exposed to temperature below -30 degrees Fahrenheit. The foam baffles shall not be left in direct sunlight for longer than 30 minutes. The ultraviolet (UV) component of sunlight may cause deterioration on the surface of the foam baffles.
NOTE
Only those foam baffles should be removed that are necessary to reach maintenance or repair areas of fuel tanks. A small number of foam baffles may be stored on the wing, protected from direct sunlight, if they are to be removed for a short time. Foam baffles shall be properly packaged and stored for extended periods of time. i. 00). Monitor atmosphere in fuel tank (WP 008
f. Allow aircraft to remain undisturbed with grounding wire attached for 15 minutes prior to performing remaining maintenance procedures.
RAC 7 - 27 February 1997
009 00
Page 12 (4) Install applicable OUTBD FUEL TANK INSPECTION DOOR (W101-L or -R, W102-L or -R, W103-L or -R, W104-L or -R and W105-L or -R) with seal and sealing compound. (QA)
Purging pressure shall not exceed 25 psi.
(5)
Purge fuel tank (NAVAIR 01-1A-35).
NOTE
Using the blower and 12 inch fan for purging, the acceptable lower explosive limit (LEL) is reached in approximately 2 hours for the No. 2 and No. 3 fuel tanks, 3 1/2 hours for the No. 1 and No. 4 fuel tanks and 48 hours for the No. 5 and No. 5A fuel tanks with an ambient air temperature of approximately 70 degrees F. In colder climates, the purging time will be considerably longer. Explosion-proof hot air blower should be used to elevate the temperature of the plurging air to at least 60 degrees F to minimize purging time. The applicable OUTBD FUEL TANK INSPECTION DOOR (W101-L or -R, W103-L or -R, 104-L or -R and W105-L or -R) is reinstalled before purging the No. 1 and No. 4 fuel tanks. j. To purge No. 1 and No. 4 fuel tanks, perform the following steps: (1) Remove applicable OUTBD FUEL TANK ACCESS panel (W111-L or -R) and remove the top four foam baffles through access. (2) Remove applicable underside OUTBD FUEL TANK INSPECTION DOOR (W101-L or -R, W102-L or -R, W103-L or -R, W104-L or -R and W105-L or -R). (3) baffles. Remove all immediately accessible foam
k. To purge No. 2 and No. 3 fuel tanks, perform the following steps: (1) Remove INBD FUEL TANK ACCESS panel (W108-L or -R). (2) access. (3) Remove top four foam baffles through
Purge fuel tank (NAVAIR 01-1A-35).
l. To purge No. 5 and No. 5A fuel tanks, perform the following steps: (1) 007 00). (2) (3) Perform aft transfer pump removal (WP
Remove manhole cover. Purge bladder cell (NAVAIR 01-1A-35).
The foam baffles shall be removed slowly from the fuel tanks to minimize the buildup of static electricity. m. Remove foam baffles slowly from fuel tank to minimize static electricity buildup.
n. Depuddle, as required, to remove residual fuel in path which personnel use to remove foam baffles (NAVAIR 01-1A-35). o. Inspect foam baffles as they are removed. Refer to FOAM BAFFLE INSPECTION CRITERIA this WP.
RAC 7 - 27 February 1997 p. After all required foam baffles are removed, complete depuddling and air purging procedures (NAVAIR 01-1A-35).
009 00
Page 13 (1) Lubricate seal with petrolatum and install on manhole cover. Secure manhole cover in place with bolts and tighten, using 180 degree tightening sequence. (QA) (2) Perform aft transfer pump installation (WP 007 00). (QA) (3) Remove tags and close circuit breakers. Remove tag from FUEL MANAGEMENT Perform fuel leak check (WP 004 00).
Any residual debris and foreign material contamination left when foam baffles are removed can accumulate in fuel system filters and strainers and decreases engine performance. q. Remove all foam baffle particles and debris from fuel tank. r. If foam baffles are to be installed, perform FOAM BAFFLE INSTALLATION this WP. If not, perform steps s through x. s. For No.1 through No. 4 fuel tanks, perform the following steps:
(4) panel. (5) (QA)
(6) On lower fuselage, install AFT FUEL PUMP and FUSELAGE FUEL TANK EQUIPMENT ACCESS panel F108. (QA)
Foam baffles shall be air dried prior to storage to reduce the potential of flammable fumes. Do not wash or flush foam with water or emulsion cleaners to remove residual fuel.
NOTE
COMPOUND, SEALING, POLYSULFIDE 4 Approximately 8 hours of operating time is required for single blower method and 5 hours for dual ventilation method. u . P l a c e w e t f o a m b a ff l e s i n s i d e d r y i n g container and allow blower to operate until foam baffles are dry to touch. Refer to FOAM BAFFLE DRYING CONTAINER FABRICATION this WP.
(1) Install applicable INBD or OUTBD FUEL TANK ACCESS panel (W108-L or -R or W111-L or -R) with seal and sealing compound on wing upper surface. (QA) (2) Remove tags from fueling control and FUEL MANAGEMENT panels. (3) Perform fuel leaks procedure (WP 004 00). (QA) t. For No. 5 and No. 5A fuel tanks, perform the following steps:
NOTE
Packaging the foam baffles in plastic bags prevents static electricity buildup on the foam baffles during handling and packing. v. Place foam baffles in plastic bags and seal with tape. w. After placing foam baffles in plastic bags, place in corrugated boxes. x. For short term exterior storage (less than 1 month), cover corrugated boxes with plastic sheet. For long term storage, place boxes in enclosed storage that is fan-ventilated.
PETROLATUM
Change 3 - 1 April 2001 8. FOAM BAFFLE INSTALLATION.
009 00
Page 14 Aircraft equipped with AFC-517 may be fueled and flown, for functional check flight purposes only, with entire foam baffle system removed from No. 1 through No. 5A fuel tanks OR with entire foam baffle system removed from No. 1 through No. 5 fuel tanks and entire foam baffle system installed in No. 5A (bladder cell) fuel tank. Foam baffle system left in No. 5A fuel tank only, typically applies to Phased Depot Maintenance (PDM) functional check flight configuration. Aircraft equipped with AFC-517 shall not be flown unless complete foam baffle system is installed in all fuel tanks. The only exception is as noted above for functional check flight.
Nomenclature
Support Equipment Required (Cont)
NOTE
Nomenclature Screen, Mesh, 1/4 in Set, Explosive Gas Detector Type Designation/ Part No. CAGE 72-8001 51906 All fuel cell maintenance shall be consistent with requirements of NAVAIR 01-1A-35. a. Defuel applicable fuel tank or fuel tanks (NAVAIR 01-75PAA-2-1, WP 011 00). b. Verify that all switches on fueling control panel are set to OFF or CLOSED and tagged. Materials Required Specification/ Part No. c . Ve r i f y t h a t a l l s w i t c h e s o n F U E L MANAGEMENT panel are set to OFF or CLOSED and tagged.
Nomenclature Compound, Sealing, Polysulfide, for Brush Application Petrolatum
NOTE
MIL-S-8802, Type II VV-L-236 The installation of foam baffles in the No. 5 and No. 5A fuel tanks requires an additional switch to be set to OFF and circuit breakers to be opened. d. For installation of foam baffles in the No. 5 and No. 5A fuel tanks, perform the following steps: Aircraft equipped with AFC-517 shall not be fueled with a portion of the foam baffle system removed or missing from any fuel tank. Incomplete baffle system in fuel tank creates voids within the foam baffle system. Foam baffles build up and retain electrostatic charge during fueling/defueling operation. This can result in electrostatic discharging between foam baffles adjacent to a void. Electrostatic discharge (arcing) in presence of fuel vapors may result in explosion. (1) Verify that FUEL DUMP switch is set to OFF and tagged. (2) At forward load center on MONITORABLE ESSENTIAL AC BUS circuit breaker panel, open and tag FUEL QUANTITY INDICATORS TANK 5A circuit breaker and FUEL TRANSFER PUMP CONT FWD and AFT circuit breakers on EXTENSION MAIN DC BUS circuit breaker panel.
RAC 7 - 27 February 1997 (3) At main load center, open and tag the following circuit breakers: Name TRANSFER PUMP FWD FUEL ABC AFT FUEL TRANS PUMP, ABC FUEL INLET VALVE CONT TANK NO. 5 Location MAIN AC BUS A forward circuit breaker panel MAIN AC BUS B forward circuit breaker panel MAIN DC BUS circuit breaker panel
009 00
Page 14A/(14B blank)
Power shall be disconnected from aircraft, static ground cable installed and external power switch shall be set to OFF and tagged before performing fuel system maintenance.
e. Remove power from aircraft (NAVAIR 01-75PAA-2-1, WP 010 00). Verify static ground cable is installed and external power switch is set to OFF and tagged (NAVAIR 01-1A-35). f. For No. 1 through No. 4 fuel tanks, open applicable INBD or OUTBD FUEL TANK ACCESS panel (W108-L or -R or W111-L or -R). g. For No. 5 and No. 5A fuel tanks, perform aft transfer pump removal (WP 007 00) and remove manhole cover.
009 00
Page 15 cause deterioration on the surface of the foam baffles. k. Arrange foam baffles at aircraft and remove from plastic bags as they are needed for immediate installation l. Verify that each foam baffle is in good condition and that markings are legible. (QA) Refer to FOAM BAFFLE INSPECTION CRITERIA this WP. m. Bounce each surface of foam baffle on 1/4 inch screen and install foam baffle in its proper location inside fuel tank according to its location identification marking. Refer to FOAM BAFFLE FABRICATION AND IDENTIFICATION this WP, Figure 1 and Figure 3 through Figure 7.
Personnel performing maintenance inside fuel tanks shall wear an air-supplied respirator at all times. Fresh air shall be circulated through the fuel tank while personnel are inside. Refer to NAVAIR 01-1A-35. No person shall enter a fuel tank unless certified safe for entry by an aviation gas free engineering technician (AVGFET). Refer to NAVAIR 01-1A-35. h. 00). i. Purge fuel tank (NAVAIR 01-1A-35). Monitor atmosphere in fuel tank (WP 008
Improper installation of the foam baffles may result in damage to the fuel probes, erroneous fuel quantity readings or electrical arcing. n. Verify foam baffle clearance from fuel tank interior components (Table 1). (QA)
NOTE
The removal of components from the fuel tanks is not required for inspection. j. Inspect all wiring, conduits, probes, tubing, pumps and valves inside fuel tank for security and serviceability. (QA) Do not intentionally remove foam baffles or trim too much foam baffle material, as it may leave excessively large void areas inside the fuel tanks. This may compromise the explosion suppression capability of the foam baffle system. Accumulation of foam baffle particles in the fuel system filters and strainers may decrease engine performance. Electric or hot wire cutters shall not be used on previously installed (wet) foam baffles nor in the immediate fuel tank repair area. The foam baffles may be dry to the touch but still contain fuel which may ignite.
The use of cotton gloves shall be avoided because they can contaminate the foam baffles with lint. Rubber gloves shall be worn for removal, handling and installation of the foam baffles. The foam baffles shall not be left in direct sunlight for longer than 30 minutes. The ultraviolet (UV) component of sunlight may
Change 1 - 1 October 1995 Table 1. Foam Baffle/Fuel Tank Component Clearances Clearance (Inches in All Directions) 4 4 4 4 4 4 4 4
009 00
Page 16 To facilitate the installation of the foam baffle system, minor trimming, slitting or slotting to accommodate wiring or tubing is permitted. Minor trimming means the removal of material from the surface of the foam baffle to alter the overall external dimensions.
Component Pump Electrically Operated Valves Drain Valves Surge Box Flapper Valves Filler Wells Scavenge Inlets Relief Valves Fuel Quantity Probes
o. Perform any necessary minor trimming and bounce each surface of foam baffle before installation.
Do not cut foam baffles inside the fuel tank. Small particles may fall inside the fuel tank. Small particles of foam may remain in the foam baffles when they are cut. Each foam baffle shall be rotated and bounced on each surface over a 1/4 inch mesh screen to dislodge trapped foam particles after cutting. Do not destroy identification markings on foam baffles. The amount of material trimmed off a single foam baffle shall not exceed 100 cubic inches and this amount shall not be removed from more than two adjacent foam baffles. The amount of material is determined by measuring the length, width and height of the proposed cut and multiplying the dimensions to give the cubic inches.
Foam baffles shall not be installed in fuel tank surge boxes. Clearances are allowed for tubing and interconnects; however, it is acceptable for the foam baffles to be in contact with tubing.
As the foam baffles are installed, small particles of foam baffle material may accumulate in the bottom of the fuel tank. As foam baffle installation progresses, any accumulated foam baffle particles shall be removed from the bottom of the fuel tank.
p . I n s t a l l f o a m b a ff l e s a n d r e m o v e a n y accumulated foam baffle particles from bottom of fuel tank as foam baffle installation progresses.
q. For No. 1 through No. 4 fuel tanks, perform the following steps:
NOTE
The foam baffle system is designed with 10 to 15 percent voiding to reduce foam baffle weight, fuel displacement and fuel retention, as well as to ease the removal and installation of foam baffles. The voiding is achieved by generous cutouts around the fuel tank components. Foam baffles may be installed without modification because the foam material is compressible, flexible and slightly elastic.
(1) Install applicable INBD or OUTBD FUEL TANK ACCESS panel (W108-L or -R or W111-L or -R) with seal and sealing compound in wing upper surface. (QA)
009 00
Page 17/(18 Blank)
A
WS 584 WS 567 WS 550 WS 533 WS 516 WS 499 WS 482 WS 465 WS 448 WS 431 WS 414 WS 397
A A A B B
A A B
A A B A
A A B
B B C
C D
D B E D F C
D D C E E F C
D C E E OB
E IB F
F D F D
D G
G E H
G E H H G E
G E H I I F I J K G L F F H E
I D
J J G G K 21 20 19 18 17 16 15 14 13 12 11 L K H M H J G K G
DETAIL A
CAVITIES 11 THROUGH 21
Figure 3. No. 1 Fuel Tank Foam Baffle Installation (Sheet 1 of 2)
009 00
Page 19/(20 Blank)
WS 397
WS 380
WS 363
WS 346
WS 324
WS 311
WS 293
WS 275
WS 257
WS 239
WS 221
A A B
B C
B B B
D C E D D F E C
C C D D
C C C C D D D
E E
E E E E F
F G
G E H F F F F
F G
H I
F G
F G H G
J J K K G H
H H H I I I H G
H I J
I J J I H J
10 9 8 7 6
J I
DETAIL A
4 3 2 1
Figure 3. No. 1 Fuel Tank Foam Baffle Installation (Sheet 2)
009 00
Page 21/(22 Blank)
WS 221
WS 197
WS 179
WS 167
WS 155
WS 137
WS 119
WS 101
WS 83
WS 65
WS 47
B OB
B IB
B B
C OB C C
C IB
C C
C OB
C IB
D D
D D D
E E
E E E E F E
E F
F F
F F
G G G G G H H H H I I I 10 9 8 7 6 5 4 3 I OB I IB I J H H OB H IB H I G G OB G IB H G
IM OB
IM IB
DETAIL A
Figure 4. No. 2 Fuel Tank Foam Baffle Installation
WS 47 WS 65 WS 83 WS 101 WS 119 WS 137 WS 155 WS 167 WS 179 WS 197 WS 221
009 00
Page 23/(24 Blank)
B B
B IB
B OB
C IB
C OB
C C
C IB
C OB
D D D
D D
E E E E E
E E
E F
F F F F F F
G G G IB G OB G G G G G H H I I I J 8 6 4 3 5 7 I IB I OB I 10 9 H IB H OB H H H I H
IM IB
IM OB
DETAIL A
Figure 5. No. 3 Fuel Tank Foam Baffle Installation
009 00
Page 25/(26 Blank)
A
WS 221 WS 239 WS 257 WS 275 WS 293 WS 311 WS 324 WS 346 WS 363 WS 380 WS 397
A A B
B B B C C C D D
B C
C C C D D D
D C E D
D D
D E
E E F E
E E
F E G F G F H H I I J G H K J K
F G
F G H G
F G
H H H G H I I I I I H J J I 5 4 3 2 1 K J 8 7 6 J J I H
10 9
DETAIL A
Figure 6. No. 4 Fuel Tank Foam Baffle Installation (Sheet 1 of 2)
009 00
Page 27/(28 Blank)
WS 397
WS 414
WS 431
WS 448
WS 465
WS 482
WS 499
WS 516
WS 533
WS 550
WS 567
WS 584
A A B
A A B
A A B
A A B B
A A
B C
D C E IB F D G E OB C
D C E E D C
D C E D
D B E
D F
G E H I F I J K G G L F F J I H F E H E G E
G E H
I D
J J K G K 20 H M H L 18 17 16 15 14 13 12 11 CAVITIES 11 THROUGH 21 19 G K 21 G J
DETAIL A
Figure 6. No. 4 Fuel Tank Foam Baffle Installation (Sheet 2)
009 00
Page 29/(30 Blank)
A
A 1 2 3 4U 4L 5 6
B C D
B C D
B C D
B C D
B C D
B C D
B C D
B C D
B
E F C 1 2 3 4U 5 6 7 8 G H D 1 2 3 4 5 6 7 8 I E 1 2 3 4 5 6 7 8 I I I I I I I G H G H G H G H G H G H G H E F E F E F E F E F E F E F
4U
J K
J K
J K
J K
J K
J K
J K L
J K
9 L L L L L L L
5U
10
N H 1U 2U 3U 4U 6 7 8 O
P I 1 2 3 4 8
DETAIL B
NO. 5 FUEL TANK CAVITIES 1 THROUGH 8
DETAIL A
NO. 5 FUEL TANK (ROTATED 180) CAVITIES 1 THROUGH 8
Figure 7. No. 5 and No. 5A Fuel Tank Foam Baffle Installation
Change 3 - 1 April 2001 (2) Remove tags from fueling control and FUEL MANAGEMENT panels. (3) (QA) Nomenclature r. For No. 5 and No. 5A fuel tanks, perform the following steps: Container, Safety, Fuel, 5 gal Coveralls Gloves, Rubber, Industrial Goggles, Industrial and Spectacles Respirator, Cartridge Organic Vapor Wrench, Torque, 0 to 150 lb-ins Perform fuel leak check (WP 004 00).
009 00
Page 31 9. FUEL SYSTEM GROUND TESTING. Support Equipment Required Type Designation/ Part No. CAGE MIL-C-14610 ZZ-G-381 GG-G-531 GG-M-125/6 81349 81348 81348 81348
PETROLATUM
(1) Lubricate seal with petrolatum and install on manhole a cover. Secure manhole cover in place with bolts and tighten, using 180 degree tightening sequence. (QA) (2) Perform aft transfer pump installation (WP 007 00). (QA) (3) Remove tags and close circuit breakers.
Materials Required Nomenclature Petrolatum Solvent, Dry Cleaning Specification/ Part No. VV-L-236 P-D-680, Type III or II (Type III preferred)
(4) Remove tags from fueling control and FUEL MANAGEMENT panels. (5) (QA) (6) On lower fuselage, install AFT FUEL PUMP and FUSELAGE FUEL TANK EQUIPMENT ACCESS panel F108. (QA) s. Perform FUEL SYSTEM GROUND TESTING this WP. (QA) Perform fuel leak check (WP 004 00). Fueling system servicing safety procedures shall be observed during fuel system ground testing (NAVAIR 06-5-502).
NOTE
Flushing of No. 1 through No. 5 and No. 5A fuel tanks is necessary when new foam baffles are installed or 25 percent or more of the foam baffles have been removed and reinstalled. a. Flush each of No. 1 through No. 5 and No. 5A fuel tanks to filter out loose foam and debris particulates (NAVAIR 01-1A-35).
Failure to reconfigure the Digital Fuel Quantity System (DFQS) for Explosive Suppressant Foam (ESF) Configuration will cause the DFQS to indicate 3.9 percent more fuel than is actually available. t. Perform Digital Fuel Quantity System Reconfiguration and Operational Check in accordance with NAVAIR 01-75PAC-2-13.1.2. (QA)
NOTE
The filling of the No. 1 through No. 5 and No. 5A fuel tanks is only necessary when new foam baffles are installed or 25 percent or more of the foam baffles have been removed and reinstalled. b. Fill No. 1 through No. 5 and No. 5A fuel tanks to capacity.
009 00
Page 32 m. Install gasket (7) and fuel inlet fitting (10) to fuel heater/strainer. n. Attach fuel inlet fitting (10) with washer (8) a n d n u t s ( 9 ) . To r q u e n u t s f r o m 7 0 t o 8 5 pound-inches. (QA)
NOTE
Do not crossfeed engines during fuel system ground testing except to test the No. 5 and No. 5A fuel tanks. c. Perform ground run of applicable engine or engines for 30 minutes at idle RPM (NAVAIR 01-75PAA-2-1, WP 010 00). d. Shut down engine or engines (NAVAIR 01-75PAA-2-1, WP 010 00). e. On fire warning panel, pull and tag applicable engine emergency shutdown handle. f . R e m o v e p o w e r f r o m a i r c r a f t ( N AVA I R 01-75PAA-2-1, WP 010 00). g. Open engine left side cowl panel P1.
NOTE
Step o should be performed if more than 1 teaspoon of foam baffle debris is found in inlet side of fuel heater/strainer. If less than 1 teaspoon of foam baffle debris is found in inlet side of fuel heater/strainer, begin with step q. o. If more than 1 teaspoon of foam baffle debris is found in inlet side of fuel heater/strainer, perform the following steps: (1) Remove nuts (4) and washers (3).
(2) Remove cap (5) with fuel strainer (2) from fuel heater/strainer. Discard packing (6).
1 If foam baffle debris is found on the outlet side of the fuel strainer, the entire fuel system is contaminated. Steps (4) through (14) shall be performed.
h. Open drain valve (1, Figure 8) to drain fuel heater/strainer of residual fuel into a safety fuel container. Close drain valve. i. Remove nuts (9) and washers (8) from fuel inlet fitting (10). j. Remove fuel inlet fitting (10) from fuel heater and strainer. k. Remove and discard gasket (7).
NOTE
If no foam baffle debris is found on the outlet side of the fuel strainer, steps (4) through (8) should be performed; then proceed to step q. (3) Check outlet side of fuel heater/strainer for foam baffle debris. If no debris is found, perform steps (4) through (8) and proceed to step q. If foam baffle debris is found on outlet side of fuel h e a t e r / s t r a i n e r, t h e e n t i r e f u e l s y s t e m i s contaminated. Perform steps (4) through (14) to clean fuel system.
NOTE
The fuel strainer of the applicable engine/fuel tank combination shall be inspected for debris from recently installed foam baffles. l. Inspect and clean any foam baffle material from inlet side of fuel heater/strainer and note if more than 1 teaspoon of foam baffle material is found. (QA)
009 00
Page 33
009008
Figure 8.
Fuel Heater/Strainer
009 00
Page 34 (12) Clean foam baffle debris from fuel boost pump inlet screen and fuel boost pump scavenger inlet screen. (13) Flush fuel system (NAVAIR 01-1A-35).
SOLVENT, DRY CLEANING, TYPE II
(14) Install foam baffles. Refer to FOAM BAFFLE INSTALLATION this WP. p. Repeat steps a through o until less than 1 teaspoon of foam baffle debris is found in inlet side of fuel heater/strainer. q. On fire warning panel, remove tag and close engine emergency shutdown handle. r. Perform engine fluid/pneumatic leak check (NAVAIR 01-75PAA-2-4, WP 004 00). (QA) s. Close engine left side cowl panel P1. Perform inspection of flap well auxiliary power unit fuel filter assembly and inspect for debris. If debris is found, remove and replace fuel filter element.
(4) Clean fuel heater/strainer (2) with dry cleaning solvent.
PETROLATUM
(5) Lubricate packing (6) with petrolatum and install on cap (5). (6) Install fuel heater/strainer (2) on cap (5).
(7) Install washers (3) and nuts (4). Torque nuts from 70 to 100 pound-inches. (QA) (8) Verify drain valve (1) is closed. (QA)
NOTE
Following step should only be performed if more than 1 teaspoon of foam baffle debris was found in inlet of No. 2 engine fuel heater/ strainer. t. Remove and replace APU fuel supply filter element (NAVAIR 01-75PAA-2-4.4, WP 010 00). u. Crossfeed fuel from No. 5 or No. 5A fuel tanks to one designated engine and perform steps c through s.
(9) Remove and replace low pressure fuel filters (NAVAIR 01-75PAA-2-4.3, WP 018 00). (10) Remove, clean and install high pressure fuel filter (NAVAIR 01-75PAA-2-4.3, WP 018 00). (11) Remove foam baffles from applicable fuel tank. Refer to FOAM BAFFLE REMOVAL AND STORAGE this WP.

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NAVAIR 01-75PAA-2-4.

AIRCRAFT FUEL SYSTEM

NAVY MODELS P-3A, P-3B AND P-3C AIRCRAFT

Published by Direction of Commander, Naval Air Systems Command

NATEC ELECTRONIC MANUAL

THIS PAGE INTENTIONALLY LEFT BLANK.

Identification No./ QA Sequence No. N39785-99-0021 48762--99--0007

Location WP009 00, pgs 1 and 31 WP003 00, pgs 1--2

THIS PAGE INTENTIONALLY LEFT BLANK.

WARNINGS APPLICABLE TO HAZARDOUS MATERIALS

Icons for Hazardous Materials and Examples of Application

LUBRIPLATE, NO. 130AA

COMPOUND, SEALING, POLYSULFIDE, MIL-S-8802, TYPE II, FOR BRUSH APPLICATION

SOLVENT, DRY CLEANING, P-D-680, TYPE II

COMPOUND, SEALING, POLYSULFIDE, FOR AIRCRAFT STRUCTURES, MIL-S-7124

Table 1. Hazardous Materials Warnings (Cont)

COMPOUND, CORROSION PREVENTIVE, MIL-C-6529

ADHESIVE, RUBBER, MIL-A-5092

THIS PAGE INTENTIONALLY LEFT BLANK.

ALPHABETICAL INDEX ORGANIZATIONAL MAINTENANCE AIRCRAFT FUEL SYSTEM

THIS PAGE INTENTIONALLY LEFT BLANK.

PURPOSE AND SCOPE.

9 . HIS TORICA L RECORD OF APP LICAB LE TECHNICAL DIRECTIVES. A historical record of

SUPPORT EQUIPMENT REQUIRED.

GGG-C-746 81348 MIL-F-16377/52

Nomenclature Adhesive, Rubber

Table of Standard Torque Values, Bolts and Nuts

PACKING TYPE COUPLING NUTS:

ALUMINUM OR STEEL UNIONS:

PLUGS AND BLEEDERS:

* ALL TORQUES ARE POUND-INCHES UNLESS OTHERWISE SPECIFIED.

Table of Standard Torque Values, Piping Assemblies

Table of Standard Torque Values, Inbuilt Torque for Self-Locking Devices

* ALL TORQUES ARE POUND-INCHES UNLESS OTHERWISE SPECIFIED.

Use of Torque Wrench Adapter

ORGANIZATIONAL MAINTENANCE DESCRIPTION AND PRINCIPLES OF OPERATIONS AIRCRAFT FUEL SYSTEM

Type/No. AFC 188 AFC 578

Date Inc. 15 Dec 70 15 AUG 98

AIRCRAFT FUEL SYSTEM DESCRIPTION.

Fuel Management Panel (AIRCRAFT NOT INCORPORATING AFC 578).

Fuel Management Panel (AIRCRAFT INCORPORATING AFC 578).

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Aircraft Fueling-Defueling and Fuel Transfer System Schematic

Fueling Control Panel

Aircraft Fuel System Circuit Schematic (Sheet 1 of 2)

Aircraft Fuel System Circuit Schematic (Sheet 2)

Crossfeed Manifold Pressure Indicator Circuit

Fuel Quantity Probes and Indicators

FUEL MANAGEMENT Panel Fuel Tanks

Fueling Control Panel

Component Fueling Adapter with Cap for Centerpoint Fueling

Component Dual Element Boost Pump

Fuel Dump Switch Fuel Quantity Test Switch

Main load center

Main load center

Fueling control panel Fueling control panel FUEL MANAGEMENT panel

Main load center

Main load center

FUEL MANAGEMENT panel On wing rear beam in wing flap well