Installation of the Fuel-Pump Suction Valve

TASK 28-21-42-400-001-A
Installation of the Fuel-Pump Suction Valve

WARNING: BE CAREFUL WHEN YOU USE CONSUMABLE MATERIALS. OBEY THE MATERIAL MANUFACTURER'S INSTRUCTIONS AND YOUR LOCAL REGULATIONS.

WARNING: THIS PROCEDURE USES A FUEL SYSTEM ITEM THAT IS IN A CATEGORY KNOWN AS A CRITICAL DESIGN CONFIGURATION CONTROL LIMITATION (CDCCL). CDCCL IDENTIFIES AN ITEM THAT CAN BE THE SOURCE OF A POSSIBLE FUEL TANK IGNITION. YOU MUST KEEP ALL CDCCL ITEMS IN THE APPROVED CONFIGURATION. DAMAGE, WEAR OR CHANGES TO A CDCCL ITEM CAN CAUSE A POSSIBLE FUEL TANK EXPLOSION.

WARNING: MAKE SURE THAT THE FLIGHT CONTROL SAFETY-LOCKS AND THE WARNING NOTICES ARE IN POSITION.

WARNING: MAKE SURE THAT THE GROUND SAFETY-LOCKS ARE IN POSITION ON THE LANDING GEAR. THIS WILL PREVENT UNWANTED MOVEMENT OF THE LANDING GEAR, AND THUS POSSIBLE INJURY TO PERSONS AND DAMAGE TO THE AIRCRAFT AND/OR EQUIPMENT.

ZONE: 540
ZONE: 640

1. Reason for the Job
Self explanatory
2. Job Set-up Information
A. Fixtures, Tools, Test and Support Equipment

REFERENCE	QTY	DESIGNATION
No specific	AR	ACCESS PLATFORM 3M (10 FT)
No specific	1	ACCESS PLATFORM 3M (10 FT)- ADJUSTABLE
No specific	AR	SAFETY BARRIER(S)

B. Consumable Materials

REFERENCE	DESIGNATION
(Material No.01ABA1)	Turbine Fuel-- Kerosene -
(Material No.03FAB1)	Mineral Oil base Grease-- Vaseline or Petrolatum -
(Material No.06ABB1)	Polysulfide Sealant-Fuel Tank Fillet -
(Material No.08BAA9)	Non Aqueous Cleaner-General - -
(Material No.14SBA1)	Textile-Lint free Cotton -

C. Work Zones and Access Panels

ZONE/ACCESS	ZONE DESCRIPTION
540	FUEL TANK
640	FUEL TANK
540AB, 540BZ, 640AB, 640BZ

D. Expendable Parts

FIG.ITEM	DESIGNATION	IPC-CSN
4	O-RING	AIPC 28-21-05-28-330
4	O-RING	AIPC 28-21-85-23-480

E. Referenced Information

REFERENCE	DESIGNATION
TASK 12-11-28-650-003-A	Pressure Refuel with Automatic Control
TASK 20-28-00-912-802-A	Electrical Bonding - General Maintenance Procedure
TASK 28-10-00-910-001-A	Safety Procedures When You Do Work in a Fuel Tank
TASK 28-10-00-910-002-A	Access to the Fuel Tanks and the Work Areas
TASK 28-21-00-710-006-A	Operational Test of the Fuel Flow through the Fuel Pumps with Gravity Feed
TASK 28-21-54-400-002-A	Installation of the Fuel Pump Strainers
TASK 28-25-00-650-001-A	Pressure Defuel
TASK 28-25-00-650-003-A	To Drain Remaining Fuel from the Wing Tanks and the Center Tank
TASK 28-25-00-650-003-A-01	To Drain Remaining Fuel from the Wing Tanks and the Center Tank
TASK 28-25-00-869-001-A	Fuel Transfer
TASK 57-27-11-000-001-A	Removal of the Access Panel
TASK 57-27-11-400-001-A	Installation of the Access Panel
TASK 57-27-12-000-002-A	Removal of the Rib 2 Access Panel 540AZ(640AZ) or 540BZ(640BZ)
TASK 57-27-12-400-002-A	Installation of the Rib 2 Access Panel 540AZ (640AZ) or 540BZ (640BZ)
Fuel-Pump Suction Valve ** ON A/C NOT FOR ALL
Fuel-Pump Suction Valve ** ON A/C NOT FOR ALL
Fuel-Pump Suction Valve ** ON A/C NOT FOR ALL

3. Job Set-up
Subtask 28-21-42-941-054-A

A. Safety Precautions

WARNING: BEFORE YOU DO WORK IN OR NEAR A FUEL TANK, MAKE SURE THAT YOU OBEY ALL THE SAFETY PROCEDURES. THIS WILL PREVENT INJURY TO PERSONS AND/OR DAMAGE TO THE AIRCRAFT.

(1) You must obey the fuel safety procedures (Ref. AMM TASK 28-10-00-910-001) when you do work in a fuel tank.
(2) Make sure that the SAFETY BARRIER(S) are in position.

Subtask 28-21-42-860-050-A ** ON A/C NOT FOR ALL

B. Aircraft Maintenance Configuration
(1) Make sure that the applicable fuel tank is defueled (Ref. AMM TASK 28-25-00-650-001).
(2) Make sure that the remaining fuel has been drained from the applicable fuel tank (Ref. AMM TASK 28-25-00-650-003).
(3) Make sure that the ACCESS PLATFORM 3M (10 FT) is below the applicable zone 540(640).
(4) Make sure that the applicable access panel 540AB(640AB) is removed (Ref. AMM TASK 28-10-00-910-002), (Ref. AMM TASK 57-27-11-000-001).
(5) Make sure that the applicable surge door 540BZ(640BZ) is open and that the 98D57004014000 HOOK-COVER (RIB2-SURGE DOORS) is installed.

Subtask 28-21-42-860-050-B ** ON A/C NOT FOR ALL

B. Aircraft Maintenance Configuration
(1) Make sure that the applicable fuel tank is defueled (Ref. AMM TASK 28-25-00-650-001).
(2) Make sure that the remaining fuel has been drained from the applicable fuel tank (Ref. AMM TASK 28-25-00-650-003).
(3) Make sure that the ACCESS PLATFORM 3M (10 FT)- ADJUSTABLE is below the applicable zone 540 (640).
(4) Make sure that the applicable access panel 540AB ( 640AB) is removed (Ref. AMM TASK 28-10-00-910-002) and (Ref. AMM TASK 57-27-11-000-001).
(5) Make sure that the applicable RIB2 access panel 540BZ ( 640BZ) is removed (Ref. AMM TASK 57-27-12-000-002).

4. Procedure
Subtask 28-21-42-420-050-A ** ON A/C NOT FOR ALL

A. Preparation for Installation
(1) Clean the component interfaces and the adjacent areas with a Textile-Lint free Cotton - (Material No.14SBA1) made moist with Non Aqueous Cleaner-General - - (Material No.08BAA9) .
(2) Make sure that the parts retained from the removed component are clean and in the correct condition.
(3) Do an inspection of the component interfaces and the adjacent area.
(4) Apply Turbine Fuel-- Kerosene - (Material No.01ABA1) or Mineral Oil base Grease-- Vaseline or Petrolatum - (Material No.03FAB1) to the new AIPC 28-21-05-28-330 O-RING (4).

Subtask 28-21-42-420-050-B ** ON A/C NOT FOR ALL

A. Preparation for Installation
(1) Clean the component interfaces and the adjacent areas with a Textile-Lint free Cotton - (Material No.14SBA1) made moist with Non Aqueous Cleaner-General - - (Material No.08BAA9) .
(2) Make sure that the parts retained from the removed component are clean and in the correct condition.
(3) Do an inspection of the component interfaces and the adjacent area.
(4) Apply Mineral Oil base Grease-- Vaseline or Petrolatum - (Material No.03FAB1) to the new AIPC 28-21-05-28-330 O-RING (4) or AIPC 28-21-85-23-480 O-RING (4).

Subtask 28-21-42-420-051-A ** ON A/C NOT FOR ALL

B. Installation of the Fuel-Pump Suction Valve
(1) Install the O-ring (4) on the fuel pipe (6).
(2) Install the fuel-pump suction valve (3) on the fuel pipe (6).
(3) Put the bonding tab (9) in position on the suction valve (3).
(4) Install the bolts (1) and (2) in their correct positions.
(5) Install the nuts (8).
(6) Tighten, by hand, the fuel-pipe connector nut (5).
(7) Make sure the fuel-pump suction valve (3) is correctly bonded:

WARNING: THIS INSTRUCTION IS APPLICABLE TO A CRITICAL DESIGN CONFIGURATION CONTROL LIMITATION (CDCCL) ITEM. CAREFULLY OBEY ALL GIVEN INSTRUCTIONS WHEN YOU DO THIS STEP. IF YOU DO NOT OBEY THESE INSTRUCTIONS, A DANGEROUS CONDITION CAN OCCUR THAT CAN CAUSE A POSSIBLE FUEL TANK EXPLOSION.

(a) Do a bonding check of the fuel-pump suction valve (3) (Ref. AMM TASK 20-28-00-912-802). The bonding resistance must be less than 10 milliohms.
(8) Apply Polysulfide Sealant-Fuel Tank Fillet - (Material No.06ABB1) to each end of the bolts (1) and (2), and to the nuts (8).

Subtask 28-21-42-420-051-B ** ON A/C NOT FOR ALL

B. Installation of the Fuel-Pump Suction Valve
(1) Install the O-ring (4) on the fuel pipe (6).
(2) Loosely install the fuel-pump suction valve (10) on the fuel pipe (6).
(3) Put the fuel-pump suction valve (10) in position on the bracket.
(4) Loosely install the bolt (11) and the nut (8).
(5) Align the link plate (9) and loosely install the bolt (2).
(6) Put the baffle (13) in position.
(7) Put the bonding tab (12) in position and install the bolt (1).
(8) Tighten all of the bolts (1), (2) and (11) and the nut (8).
(9) Install the bolts (3).
(10) Install the suction valve strainer assembly (Ref. AMM TASK 28-21-54-400-002).
(11) Tighten, by hand, the fuel-pipe connector nut (5).
(12) Make sure that the fuel-pump suction valve (10) is correctly bonded:

(a) Do a bonding check of the fuel-pump suction valve (10) (Ref. AMM TASK 20-28-00-912-802). The bonding resistance must be less than 10 milliohms.
(13) Apply Polysulfide Sealant-Fuel Tank Fillet - (Material No.06ABB1) to the bolts (1), (2), (3), (11) and to the nut (8).

Subtask 28-21-42-410-050-A ** ON A/C NOT FOR ALL

C. Close Access
(1) Make sure that the work area is clean and clear of tools and other items.
(2) Remove the 98D57004014000 HOOK-COVER (RIB2-SURGE DOORS) from the RIB 2 surge door.
(3) Close the applicable surge door 540BZ(640BZ).
(4) Install the applicable wing access panel 540AB(640AB) (Ref. AMM TASK 28-10-00-910-002), (Ref. AMM TASK 57-27-11-400-001).

Subtask 28-21-42-410-050-B ** ON A/C NOT FOR ALL

C. Close Access
(1) Make sure that the work area is clean and clear of tools and other items.
(2) Install the applicable RIB2 access panel 540BZ ( 640BZ) (Ref. AMM TASK 57-27-12-400-002).
(3) Install the applicable wing access panel 540AB ( 640AB) (Ref. AMM TASK 57-27-11-400-001).

Subtask 28-21-42-710-050-A

D. Operational Test
(1) Do an operational test of the fuel flow through the pumps by gravity feed (Ref. AMM TASK 28-21-00-710-006).
(2) Make sure that the fuel-pump suction valve (3) operates correctly.

Subtask 28-21-42-650-051-A

E. Fuel Configuration
(1) Refuel, defuel or transfer fuel as necessary (Ref. AMM TASK 12-11-28-650-003), (Ref. AMM TASK 28-25-00-650-001) or (Ref. AMM TASK 28-25-00-869-001).

5. Close-up
Subtask 28-21-42-942-050-A

A. Removal of Equipment
(1) Remove the safety barriers.
(2) Remove the WARNING NOTICE(S).
(3) Remove the access platform(s).
(4) Remove the ground support and maintenance equipment, the special and standard tools and all other items.

[Rev.10 from 2021] 2026.04.02 06:17:25 UTC