12-13-01 Defueling Procedure

a display error will occur. The correct number values will not be shown in the LEFT / RIGHT – QTY and PRESELECT TOTAL QTY display windows. 5.5 Lift the red switch guard on the GSCP and select the GSCP PANEL POWER switch to the ON position. 5.6 On the GSCP, make sure that number values are shown in the LEFT / RIGHT – QTY and PRESELECT TOTAL QTY display windows. 5.7 Select and hold the HIGH LEVEL TEST / DISPLAY BIT DATA switch to the HIGH LEVEL TEST position. Make sure that the results are as follows: • The amber HIGH LEVEL WARN lights come on • Fuel system fault messages are not shown on the GSCP display NOTE The HIGH LEVEL TEST / DISPLAY BIT DATA toggle switch is spring-loaded to the center position. The switch must be manually held in the HIGH LEVEL TEST or DISPLAY BIT DATA position for necessary results. 5.8 Release the HIGH LEVEL TEST / DISPLAY BIT DATA switch from the HIGH LEVEL TEST position. Make sure that the results are as follows: • The amber HIGH LEVEL WARN lights go off • Fuel system fault messages are not shown on the GSCP display 5.9 Select and hold the HIGH LEVEL TEST / DISPLAY BIT DATA switch to the DISPLAY BIT DATA position and make sure that: • The PRESELECT TOTAL QTY displays NO FAULT 5.10 Release the HIGH LEVEL TEST / DISPLAY BIT DATA switch from the DISPLAY BIT DATA position. Make sure that the results are as follows: • The PRESELECT TOTAL QTY shows the correct PRESELECT TOTAL QTY • Fuel system fault messages are not shown on the GSCP display 6 The defueling procedures are provided as follows: 12-13-01 Defueling Procedure - Defuel September 30/23 Page 4 MAINTENANCE MANUAL • Step 7 - Suction Defuel Through The Pressure Fueling / Defueling Adapter • Step 8 - Pump Assisted Defuel Through The Defuel Valve Located in WTBF • Step 9 - Draining Fuel From The Manual Water / Fuel Drain Valves 7 Suction Defuel Through The Pressure Fueling / Defueling Adapter 7.1 Open the single point refuel door as follows (see Figure 4. Right Wing Lower Surface Access Doors and Panels): 621RB CAUTION BEFORE THE AIRCRAFT IS DEFUELED, MAKE SURE THAT THERE IS A GROUND FROM THE AIRCRAFT TO THE FUEL SOURCE. NOTE Monitor the fuel quantity indicator to prevent a fuel unbalance condition more than 1000 pounds (454 kg). When the wing tanks have been fully drained for an extended time, it can be necessary to bleed the APU fuel system before an APU start. Refer to APU Fuel System - Bleed, 28-00-03. 7.2 Make sure that the bond wire is connected from the fuel carrier to the aircraft ground receptacle on the GSCP. See Figure 2. Ground Service Control Panel and Figure 3. Satisfactory / Not Satisfactory Bonding Procedures. 7.3 Remove the cap from the pressure fuel / defuel adapter. See Figure 5. Single Point Fuel / Defuel Adapter. 7.4 Connect the single point fuel nozzle to the pressure fuel / defuel adapter. 7.5 Open the single point fuel nozzle to defuel the aircraft. WARNING THE USE OF BOOST PUMPS TO BALANCE FUEL IS ONLY PERMITTED WHEN FUEL LEVELS ARE ABOVE 5000 LBS PER WING. BELOW 5000 POUNDS, THE INTERTANK VALVE MUST BE OPENED TO ALLOW FUEL TO BALANCE. FUEL PUMPS MUST BE SUBMERGED IN FUEL. NEVER OPERATE DRY. THIS CAN RESULT IN AIRCRAFT DAMAGE OR INJURY TO PERSONNEL. 12-13-01 Defueling Procedure - Defuel September 30/23 Page 5 MAINTENANCE MANUAL CAUTION FUEL IMBALANCE IS NOT TO BE MORE THAN 1000 POUNDS (454 KG). 7.6 Start defueling at a fuel flow rate not more than 50 gpm. NOTE If the rate of flow is more than 50 gpm, there will be no suction and defueling will stop. Monitor the fuel quantity indicator to prevent a fuel unbalance condition more than 1000 pounds (454 kg). If power is available, the fuel quantity can be monitored at the GSCP to prevent an unbalanced fuel condition. 7.7 When the fuel flow stops, close the single point fuel nozzle. 7.8 Disconnect the single point fuel nozzle from the pressure fuel / defuel adapter. 7.9 Install the cap on the pressure fuel / defuel adapter and make sure that the cap is locked. 7.10 If power is available, select the GSCP PANEL POWER switch to the OFF position and close the red switch guard on the GSCP. 7.11 Press and release the GND SVC BUS SW switch. See Figure 2. Ground Service Control Panel. NOTE The GND SVS BUS SW switch is below the GSCP. 7.12 Make sure that the light in the GND SVC BUS SW switch goes off. 7.13 Do Open / Close Checks - Visual Examination, 20-00-02. 7.14 Close the single point refuel door as follows (see Figure 4. Right Wing Lower Surface Access Doors and Panels): 621RB 7.15 If additional fuel removal from the wings is necessary, go to Step 9. 7.16 If defuel is complete, go to Step 10. 8 Pump Assisted Defuel Through The Manual Defuel Valve Located in WTBF 12-13-01 Defueling Procedure - Defuel September 30/23 Page 6 MAINTENANCE MANUAL WARNING PUMP ASSISTED DEFUELING IS ONLY PERMITTED ABOVE 5000 POUNDS PER WING. BELOW 5000 POUNDS, DEFUELING MUST BE ACCOMPLISHED THROUGH OTHER METHODS SUCH AS SUCTION DEFUELING OR DRAINING. 8.1 Remove the WTBF panel as follows (refer to Aft WTBF Panels - Removal / Installation, 53-93-01): 193AL NOTE Use the numbers in parentheses ( ) in connection with Figure 6. Manual Defuel Valve. 8.2 Remove the defuel drain valve end cap (2) from the defuel drain valve (1). CAUTION BEFORE THE AIRCRAFT IS DEFUELED, MAKE SURE THAT THERE IS A GROUND FROM THE AIRCRAFT TO THE FUEL SOURCE. NOTE Monitor the fuel quantity indicator to prevent a fuel unbalance condition more than 1000 pounds (454 kg). When the wing tanks have been fully drained for an extended time, it can be necessary to bleed the APU fuel system before an APU start. Refer to APU Fuel System - Bleed, 28-00-03. 8.3 Make sure that the bond wire is connected from the ground refueling carrier to the aircraft ground receptacle on the GSCP. See Figure 2. Ground Service Control Panel and Figure 3. Satisfactory / Not Satisfactory Bonding Procedures. 8.4 Attach the hose to the defuel drain valve (1) and connect the hose to the fuel carrier. 12-13-01 Defueling Procedure - Defuel September 30/23 Page 7 MAINTENANCE MANUAL WARNING MAKE SURE THAT ALL PERSONNEL AND EQUIPMENT ARE CLEAR OF THE FLIGHT CONTROL SURFACES BEFORE ELECTRICAL POWER IS APPLIED OR IT CAN RESULT IN SERIOUS INJURY / DEATH TO PERSONNEL OR DAMAGE TO THE AIRCRAFT. WHEN ELECTRICAL POWER IS APPLIED TO THE AIRCRAFT, IT CAN CAUSE THE FLIGHT CONTROL SURFACES TO MOVE. 8.5 Apply electrical power to the aircraft.Refer to Electrical Power Application - General Maintenance, 20-20-01. 8.6 Remove the tags, safety clips and close the circuit breakers: NOMENCLATURE PANEL LOCATION L MAIN FUEL PUMP Left PDB LEFT ESS DC R MAIN FUEL PUMP Right PDB RIGHT ESS DC 8.7 Remove the collars and close the SSPCs: For information on the operation of the SSPCs, refer to SSPC - General Maintenance, 20-20-02. NOMENCLATURE PANEL LOCATION ALT FUEL PUMP L TSC 2808 ALT FUEL PUMP R TSC 2809 FUEL XFLO VLV CLS TSC 2813 FUEL XFLO VLV OPN TSC 2814 8.8 On the OHPTS Fuel page, make sure that the following switches are in the OFF position: • L MAIN PUMP and R MAIN PUMP • L ALT PUMP and R ALT PUMP CAUTION THE DEFUEL MUST BE DONE WITH THE WINGS LEVEL LATERALLY AND NOSE IN THE NORMAL GROUND ATTITUDE. DEFUEL WITH ONE WING LOWER THAN THE OTHER CAN RESULT IN TRAPPED FUEL IN THE WINGS. 8.9 Open the defuel drain valve (1). 8.10 On the OHPTS Fuel page, make the selections as follows: 8.10.1 Select the L Main Pump and R Main Pump switches to on. 12-13-01 Defueling Procedure - Defuel September 30/23 Page 8 MAINTENANCE MANUAL NOTE The L Main Pump and R Main Pump switches will change from white to green. The L Main Pump and R Main Pump switches may turn to amber if back pressure in the defuel line is not sufficient. This is satisfactory. 8.10.2 Select L Alt Pump and R Alt Pump switches to on. NOTE The L Alt Pump and R Alt Pump switches will change from white to green. The L Alt Pump and R Alt Pump switches may turn amber if back pressure in the defuel line is not sufficient. This is satisfactory. 8.10.3 Select Crossflow to Open. 8.10.4 Select Accept. NOTE Switch will change to green. WARNING FUEL PUMPS MUST BE SUBMERGED IN FUEL. NEVER OPERATE DRY. THIS CAN RESULT IN AIRCRAFT DAMAGE OR INJURY TO PERSONNEL. PUMP ASSISTED DEFUELING IS ONLY PERMITTED ABOVE 5000 POUNDS PER WING. BELOW 5000 POUNDS, DEFUELING MUST BE ACCOMPLISHED THROUGH OTHER METHODS SUCH AS SUCTION DEFUELING OR DRAINING. CAUTION FUEL IMBALANCE IS NOT TO BE MORE THAN 1000 POUNDS (453.6 KG). 8.11 Monitor the fuel quantities during the defuel. 8.11.1 Ensure fuel level does not fall below 5000 pounds per wing. 8.12 When the aircraft defuel is complete, on the OHPTS Fuel page, make the selections as follows: 12-13-01 Defueling Procedure - Defuel September 30/23 Page 9 MAINTENANCE MANUAL 8.12.1 Select the L Main Pump and R Main Pump switches to off. NOTE Switch will change from amber to white. 8.12.2 Select L Alt Pump and R Alt Pump switches to off. NOTE Switch will change from amber to white. 8.12.3 Select Crossflow to Closed. 8.12.4 Select Accept. NOTE Switch will change to white. 8.13 Close the defuel drain valve (1). 8.14 Select the GSCP PANEL POWER switch to the OFF and close the red switch guard on the GSCP. 8.15 Press and release the GND SVC BUS SW switch. See Figure 2. Ground Service Control Panel. NOTE The GND SVS BUS SW switch is below the GSCP. 8.15.1 Make sure that the light in the GND SVC BUS SW switch goes off. 8.16 Pull and install the collars on the SSPCs: For information on the operation of the SSPCs, refer to SSPC - General Maintenance, 20-20-02. NOMENCLATURE PANEL LOCATION ALT FUEL PUMP L TSC 2808 ALT FUEL PUMP R TSC 2809 FUEL XFLO VLV CLS TSC 2813 FUEL XFLO VLV OPN TSC 2814 8.17 Pull, tag and install the safety clips on the circuit breakers: 12-13-01 Defueling Procedure - Defuel September 30/23 Page 10 MAINTENANCE MANUAL NOMENCLATURE PANEL LOCATION L MAIN FUEL PUMP Left PDB LEFT ESS DC R MAIN FUEL PUMP Right PDB RIGHT ESS DC 8.18 Remove electrical power from the aircraft. Refer to Electrical Power Application - General Maintenance, 20-20-01. 8.19 Disconnect the hose from the defuel drain valve (1) and the fuel carrier. 8.20 Install the defuel drain valve end cap (2). 8.21 Torque the defuel drain valve end cap (2) to 695 - 775 inch-pounds (78.5 - 87.5 Nm). _____ TECH _____ INSP _____ 8.22 Inspect the work area for foreign objects and damage. 8.23 Install the WTBF panel as follows (refer to Aft WTBF Panels - Removal / Installation, 53-93-01): 193AL 8.24 If additional fuel removal from the wings is necessary, go to Step 9. 8.25 If defuel is complete, go to Step 10. 9 Draining Fuel From The Manual Water / Fuel Drain Valves If necessary, drain the remaining fuel from the wings as follows: 9.1 Open the necessary access doors as follows (see Figure 7. WTBFs, Access Doors and Panels): 191AL-1 191AL-2 191AR-1 191AR-2 9.2 If necessary, position the Form-A-Funnel flexible draining tool below the water / fuel drain valves. NOTE The Form-A-Funnel flexible drain tool is used to stop the wind from splashing the fuel as it drains. It is also used to prevent fuel from draining into the WTBF. There are six (three per wing) water / fuel drain valves on the underside of each wing. See Figure 8. Water / Fuel Drain Valves. CAUTION MAKE SURE THAT THE STEM OF THE VALVE IS FULLY PUSHED UP BEFORE IT IS TURNED. IF IT IS NOT FULLY UP, IT CAN CAUSE DAMAGE TO THE INTERNAL PINS THAT LOCK THE VALVE. 12-13-01 Defueling Procedure - Defuel September 30/23 Page 11 MAINTENANCE MANUAL NOTE Use a correct fuel container to catch the fuel from the manual water / fuel valves. 9.3 Open the necessary manual water / fuel drain valves as follows (see Figure 8. Water / Fuel Drain Valves): 9.3.1 To open the valve, use a cross-slot (Phillips type) screwdriver, positioned in the center of the valve and push the valve up. 9.3.2 To keep the valve in the open position, with the valve pushed in the up position, turn the stem of the valve approximately 90° (1/4 turn) counterclockwise. 9.4 When the necessary fuel draining is complete, close the necessary manual water / fuel drain valves as follows (see Figure 8. Water / Fuel Drain Valves): 9.4.1 Use a cross-slot (Phillips type) screwdriver positioned in the center of the stem of the valve and turn it approximately 90° (1/4 turn) clockwise. 9.4.2 The valve stem should return to the down position. 9.4.3 Make sure that the valve is closed (down) and is flush with the wing surface. 9.5 If necessary, remove the Form-A-Funnel flexible draining tool from below the water / fuel drain valves. 9.6 Inspect the work area for foreign objects and damage. 9.7 Do Open / Close Checks - Visual Examination, 20-00-02. 9.8 Close the necessary access doors as follows (see Figure 7. WTBFs, Access Doors and Panels): 191AL-1 191AL-2 191AR-1 191AR-2 10 Remove the bond wire from the receptacle in the GSCP. See Figure 2. Ground Service Control Panel. 11 Inspect the work area for foreign objects and damage. 12 Do Open / Close Checks - Visual Examination, 20-00-02. 13 Close the GSCP access door as follows (see Figure 2. Ground Service Control Panel): 164AR-1 Requirements After Job Completion Inspect the work area for foreign objects and damage. Record all maintenance in compliance with the National Aviation Authority Regulations. 12-13-01 Defueling Procedure - Defuel September 30/23 Page 12 MAINTENANCE MANUAL OP CL FWD A C CROSS-FLOW SHUT-OFF VALVE APU FUEL SHUT-OFF VALVE INTERTANK SHUT-OFF VALVE D OP CL FULL OPEN POSITION 59734-TIL040600-001 G500 C FULL CLOSED POSITION ENGINE FUEL SHUT-OFF VALVE MOTOR FULL CLOSED POSITION FULL OPEN POSITION B B D A Intertank Shut-off Valve Figure 1 12-13-01 Defueling Procedure - Defuel September 30/23 Page 13 MAINTENANCE MANUAL A FWD GND SVC BUS SW GROUND HERE 59734-TIL040602-001 GND SVC BUS SWITCH A G500 Ground Service Control Panel Figure 2 12-13-01 Defueling Procedure - Defuel September 30/23 Page 14 MAINTENANCE MANUAL GROUNDING (NOT SATISFACTORY) G500 59734-TIL019089-001 BONDING AND GROUNDING (NOT SATISFACTORY) BONDING (SATISFACTORY) Satisfactory / Not Satisfactory Bonding Procedures Figure 3 12-13-01 Defueling Procedure - Defuel September 30/23 Page 15 MAINTENANCE MANUAL 59734-TIL019005-001 G500 621RB 621BB 621CB 621DB 621EB 621FB 621GB 621HB 621JB 621KB 621LB 621MB 621NB 621PB 621QB 622AB 622BB 622CB 622DB 641AB 641BB 621AB 621AZ (INSIDE WING) 621BZ (INSIDE WING) VIEW LOOKING UP VIEW LOOKING UP 691EB 691DB 691CB 691BB 691AB 672AB 672BB FWD A RIGHT WING A B B RIGHT WING Right Wing Lower Surface Access Doors and Panels Figure 4 12-13-01 Defueling Procedure - Defuel September 30/23 Page 16 MAINTENANCE MANUAL A G500 59734-TIL019316-001 SINGLE POINT REFUEL ADAPTER A Single Point Fuel / Defuel Adapter Figure 5 12-13-01 Defueling Procedure - Defuel September 30/23 Page 17 MAINTENANCE MANUAL A FWD 59734-TIL040599-001 G500 A 2 1 Manual Defuel Valve Figure 6 12-13-01 Defueling Procedure - Defuel September 30/23 Page 18 MAINTENANCE MANUAL FS 423 FS 476 FS 371 WL 37 FS 806 WL 33 FS 691 163AL 161BB 161AB 161CB 164AR 164AR-1 164AR-2 165AL 165AL-2 163AL-1 191AL 195AL 191AL-2 196AL 197AR 191AR 191AR-1 191AB 191AL-1 193CL-3 193CL 193BL-1 193AL 194AR-2 193CL-2 194AR-3 194AR-1 194AR 193BL 193CL-1 191AR-2 165AL-1 A FWD G500 59734-TIL018988-001 FS 638 VIEW LOOKING DOWN A WTBFs, Access Doors and Panels Figure 7 12-13-01 Defueling Procedure - Defuel September 30/23 Page 19 MAINTENANCE MANUAL 59734-TIL040601-001 G500 A A A A TYPICAL VIEW LOOKING UP Water / Fuel Drain Valves Figure 8 12-13-01 Defueling Procedure - Defuel September 30/23 Page 20