Installation of the Refuel/Defuel Coupling Element-Assembly

TASK 28-25-41-400-006-A
Installation of the Refuel/Defuel Coupling Element-Assembly

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

WARNING: PUT THE SAFETY DEVICES AND THE WARNING NOTICES IN POSITION BEFORE YOU START A TASK ON OR NEAR:

THE FLIGHT CONTROLS
THE FLIGHT CONTROL SURFACES
THE LANDING GEAR AND THE RELATED DOORS
COMPONENTS THAT MOVE.

MOVEMENT OF COMPONENTS CAN KILL OR CAUSE INJURY TO PERSONS AND/OR CAN CAUSE DAMAGE TO THE EQUIPMENT.

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 4M (13 FT)
No specific	AR	SAFETY BARRIER(S)
No specific	Torque wrench: range to between 3.4 and 3.0 m.N (30.09 and 26.55 lbf.in )
No specific	Torque wrench: range to between 0.34 and 0.3 m.daN (30.09 and 26.55 lbf.in )
No specific	Torque wrench: range to between 0.4 and 0.3 m.daN (35.40 and 26.55 lbf.in )

B. Consumable Materials

REFERENCE	DESIGNATION
(Material No.01ABA1)	Turbine Fuel-- Kerosene -
(Material No.03QBA1)	Dry lubricant-General Assembly - -
(Material No.08BAA9)	Non Aqueous Cleaner-General - -
(Material No.14SBA1)	Textile-Lint free Cotton -

C. Work Zones and Access Panels

ZONE/ACCESS	ZONE DESCRIPTION
622HB
522HB

D. Expendable Parts

FIG.ITEM	DESIGNATION	IPC-CSN
23	SHIM	AIPC 28-25-41-01-030
3	SHIM	AIPC 28-25-41-01-030
2	O-RING	AIPC 28-25-41-01-040
22	O-RING	AIPC 28-25-41-01-040

E. Referenced Information

REFERENCE	DESIGNATION
TASK 12-11-28-650-003-A	Pressure Refuel with Automatic Control
TASK 28-00-00-910-001-A	Fuel Safety Procedures
TASK 57-41-37-000-006-A	Removal of the Access Panels
TASK 57-41-37-400-006-A	Installation of the Access Panels
Refuel/Defuel Coupling Element Assembly - Location and Detail ** ON A/C NOT FOR ALL
Refuel/Defuel Coupling Element Assembly - Location and Detail ** ON A/C NOT FOR ALL
Dimensions and Positions, Right Wing
Dimensions and Positions, Left Wing ** ON A/C NOT FOR ALL

3. Job Set-up
Subtask 28-25-41-941-061-A

A. Safety Precautions

WARNING: OBEY THE FUEL SAFETY PROCEDURES.

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

Subtask 28-25-41-860-054-A ** ON A/C NOT FOR ALL

B. Aircraft Maintenance Configuration
(1) Make sure that the ACCESS PLATFORM 4M (13 FT) is below the applicable refuel/defuel coupling 100QM(40QM).
(2) Make sure that the applicable access panel 522HB(622HB) is removed.

Subtask 28-25-41-860-054-B ** ON A/C NOT FOR ALL

B. Aircraft Maintenance Configuration
(1) Make sure that the ACCESS PLATFORM 4M (13 FT) is below the refuel/defuel coupling 40QM.
(2) Make sure that the access panel 622HB is removed.

Subtask 28-25-41-865-054-A

C. Make sure that this(these) circuit breaker(s) is(are) open, safetied and tagged:

PANEL	DESIGNATION	FIN	LOCATION
** ON A/C NOT FOR ALL
49VU	FLIGHT CONTROLS/SLT/CTL AND MONG/SYS1	5CV	B06
** ON A/C NOT FOR ALL
49VU	FLIGHT CONTROLS/SLT/CTL AND MONG/SYS1	5CV	B01
** ON A/C NOT FOR ALL
121VU	FUEL/RFL/DFL/SPLY	2QU	L24
121VU	FUEL/RFL/DFL/XFR/DEFUEL/VALVE	1QU	L23
** ON A/C ALL
121VU	FLIGHT CONTROLS/SLT/CTL/SYS2	7CV	R21
** ON A/C NOT FOR ALL
121VU	FUEL/RFL/DFL/SPLY	2QU	L23
121VU	FUEL/RFL/DFL/XFR/DEFUEL/VALVE	1QU	L22

4. Procedure
Subtask 28-25-41-420-058-A

A. Preparation for Installation
(1) Clean the component interface and/or the adjacent area with a clean Textile-Lint free Cotton - (Material No.14SBA1) made moist with Non Aqueous Cleaner-General - - (Material No.08BAA9) .
(2) Do an inspection of the component interfaces and the adjacent area.
(3) Make sure that the parts retained from the removed component are clean and in the correct condition.

Subtask 28-25-41-420-059-A

B. Installation of the Refuel/Defuel Coupling Element-Assembly
(1) If the coupling cap is attached to the coupling with a lanyard, continue the procedure as follows:
(a) Apply Turbine Fuel-- Kerosene - (Material No.01ABA1) or Dry lubricant-General Assembly - - (Material No.03QBA1) to the new AIPC 28-25-41-01-040 O-RING (2).
(b) Install the O-rings (2) and the laminated shims (3).
(c) Install the element assembly (4) and the shroud ring (5) in their correct position.
(d) Install the washers (6) and the bolts (7). Torque the bolts (7) in an opposite sequence to between 0.34 and 0.3 m.daN (30.09 and 26.55 lbf.in )

.
(e) Install the lanyard (9) on the attachment lug of the shroud ring (5) with the bolt (10) and the nut (11).

CAUTION: MAKE SURE THAT THE HANDLE OF THE REFUEL COUPLING CAP POINTS AFT WHEN THE CAP IS CLOSED AND LOCKED.

(f) Install the coupling cap (8) on the coupling (1).
1 You can change the installation direction of the shroud ring (5) when you install the coupling cap (8). This is to prevent the possible interference of the coupling cap (8) and the cable attach lug on the shroud ring (5).

Subtask 28-25-41-420-061-A

C. Installation of the Refuel/Defuel Coupling Element-Assembly
(1) If the coupling cap is attached to the coupling with a chain, continue the procedure as follows:
(a) Apply Turbine Fuel-- Kerosene - (Material No.01ABA1) or Dry lubricant-General Assembly - - (Material No.03QBA1) to the new AIPC 28-25-41-01-040 O-RING (22).
(b) Install the O-rings (22) and the laminated shims (23).
(c) Install the element assembly (24) and the shroud ring (25) in their correct position.
(d) Install the washers (26), the attachment tag (30) and the bolts (27).

CAUTION: MAKE SURE THAT THE HANDLE OF THE REFUEL COUPLING CAP POINTS AFT WHEN THE CAP IS CLOSED AND LOCKED.

(e) Torque the bolts (27) in an opposite sequence to between 0.34 and 0.3 m.daN (30.09 and 26.55 lbf.in )

NOTE: The chain (29) is spring loaded into a protective sleeve on the coupling cap (28).

(f) Install the coupling cap (28) on the coupling (21).
1 You can change the installation direction of the shroud ring (25) when you install the coupling cap (28). This is to prevent the possible interference of the coupling cap (28) and the cable attach lug on the shroud ring (25).

Subtask 28-25-41-410-062-A ** ON A/C NOT FOR ALL

D. Close Access
(1) Install the applicable access panels 522HB(622HB).

Subtask 28-25-41-820-054-A

DELETED

Subtask 28-25-41-820-054-B

DELETED

Subtask 28-25-41-820-054-F ** ON A/C NOT FOR ALL

E. Adjustment of the Coupling when you install the new Shims
(1) If the coupling cap is attached to the coupling with a lanyard, continue as follows:
(a) Make sure that these dimensions are correct:

Dimensions and Positions, Right Wing ** ON A/C NOT FOR ALL

Dimensions and Positions, Left Wing ** ON A/C NOT FOR ALL

Dimension 'a' must be equal at all positions around the coupling cap (8) +/- 0.5 mm (0.0197 in.)
Dimension 'x' must not be more than 1.0 mm (0.0394 in.)
Dimension 'y' must not be more than 1.0 mm (0.0394 in.)
Dimension 'z' must not be more than 0.13 mm (0.0051 in.).

(b) If dimension 'a' is incorrect, do the steps that follow:
1 Temporarily remove applicable access panel 522HB ( 622HB) (Ref. AMM TASK 57-41-37-000-006).

Refuel/Defuel Coupling Element Assembly - Location and Detail ** ON A/C NOT FOR ALL

2 Remove the coupling cap (8) from the coupling (1).
3 Remove the nut (11) and the bolt (10) to remove the lanyard (9) from the attachment lug of the shroud ring (5).
4 Hold the element assembly (4) and remove the bolts (7) and the washers (6).
5 Remove the shroud ring (5), the element assembly (4) and the laminated shim(s) (3).
6 Remove and discard the O-ring (2).
7 Adjust the thickness of the AIPC 28-25-41-01-030 SHIM (3) until dimension 'x', 'y' and/or dimension 'z' is/are correct.

NOTE: The maximum permitted thickness is 4.4 mm (0.1732 in.) and the minimum permitted thickness is 0 mm (0 in.).

8 Lubricate the new AIPC 28-25-41-01-040 O-RING (2) with Turbine Fuel-- Kerosene - (Material No.01ABA1) or Dry lubricant-General Assembly - - (Material No.03QBA1) .
9 lnstall the O-ring (2) and the laminated shim(s) (3).
10 lnstall the element assembly (4) and the shroud ring (5) in their correct position.
11 lnstall the washers (6) and the bolts (7).
12 TORQUE the bolts (7) in an opposite sequence to between 3.4 and 3.0 m.N (30.09 and 26.55 lbf.in )

.
13 lnstall the lanyard (9) on the attachment lug of the shroud ring (5) with the bolt (10) and the nut (11).
14 TORQUE the nut (11) to between 0.4 and 0.3 m.daN (35.40 and 26.55 lbf.in )

CAUTION: MAKE SURE THAT THE HANDLE OF THE REFUEL COUPLING CAP POINTS AFT WHEN THE CAP IS CLOSED AND LOCKED.

15 lnstall the coupling cap (8) on the coupling (1).
16 Install applicable access panel 522HB ( 622HB) (Ref. AMM TASK 57-41-37-400-006).
17 Measure the dimensions 'x', 'y' and 'z' again to make sure that they are correct.
(2) If the coupling cap is attached to the coupling with a chain, continue as follows:
(a) Make sure that these dimensions are correct:

Dimensions and Positions, Right Wing ** ON A/C NOT FOR ALL

Dimensions and Positions, Left Wing ** ON A/C NOT FOR ALL

Dimension 'a' must be equal at all positions around the coupling cap (28) +/- 0.5 mm (0.0197 in.)
Dimension 'x' must not be more than 1.0 mm (0.0394 in.)
Dimension 'y' must not be more than 1.0 mm (0.0394 in.)
Dimension 'z' must not be more than 0.13 mm (0.0051 in.).

(b) If dimension 'a' is incorrect, do the steps that follow:
1 Temporarily remove access panel 522HB ( 622HB) (Ref. AMM TASK 57-41-37-000-006).
2 Remove the coupling cap (28) from the coupling (21).

NOTE: The chain (29) is spring-loaded into a protection sleeve on the coupling cap (28).

3 Hold the element assembly (24) and remove the bolts (27), the washers (26) and the attachment tag (30).
4 Remove the shroud ring (25), the element assembly (24) and the laminated shim(s) (23).
5 Remove and discard the O-ring (22).
6 Adjust the thickness of the AIPC 28-25-41-01-030 SHIM (23) until dimension 'x', 'y' and/or dimension 'z' is/are correct.

NOTE: The maximum permitted thickness is 4.4 mm (0.1732 in.) and the minimum permitted thickness is 0 mm (0 in.).

7 Lubricate the new AIPC 28-25-41-01-040 O-RING (22) with Turbine Fuel-- Kerosene - (Material No.01ABA1) or Dry lubricant-General Assembly - - (Material No.03QBA1) .
8 Install the O-ring (22) and the laminated shim(s) (23).
9 Install the element assembly (24) and the shroud ring (25) in their correct positions as follows:
a Adjust the element assembly (24) and the shroud ring (25) to make sure that the lug does not touch the refuel cap.
b Make sure that the position of the shroud support ring is 22.30 deg (22.3 deg) to the chain attachment lug.
10 Install the washers (26), the attachment tag (30) and the bolts (27).
11 TORQUE the bolts (27) in an opposite sequence to between 3.4 and 3.0 m.N (30.09 and 26.55 lbf.in )

NOTE: The chain (29) is spring-loaded into a protection sleeve on the coupling cap (28).

12 Install the chain (29) on the attachment tag (30).

CAUTION: MAKE SURE THAT THE HANDLE OF THE REFUEL COUPLING CAP POINTS AFT WHEN THE CAP IS CLOSED AND LOCKED.

13 Install the coupling cap (28) on the coupling (21).
14 Install applicable access panel 522HB ( 622HB) (Ref. AMM TASK 57-41-37-400-006).
15 Measure the dimensions 'x', 'y' and 'z' again to make sure that they are correct.

Subtask 28-25-41-860-055-A ** ON A/C NOT FOR ALL

F. Preparation for Test
(1) If the coupling-cap is attached to the coupling with a lanyard, continue as follows:
(a) Refuel the aircraft through the coupling (1) (Ref. AMM TASK 12-11-28-650-003).
(b) Remove the applicable access panel 522HB ( 622HB).
(2) If the coupling-cap is attached to the coupling with a chain, continue as follows:
(a) Refuel the aircraft through the coupling (21) (Ref. AMM TASK 12-11-28-650-003).
(b) Remove the applicable access panel 522HB ( 622HB).

Subtask 28-25-41-410-062-B ** ON A/C NOT FOR ALL

G. Close Access
(1) Install the access panel 622HB.

Subtask 28-25-41-820-054-D ** ON A/C NOT FOR ALL

H. Adjustment of the Coupling when you install the new Shims
(1) If the coupling cap is attached to the coupling with a lanyard, continue as follows:
(a) Make sure that these dimensions are correct:

Dimensions and Positions, Right Wing ** ON A/C NOT FOR ALL

Dimension 'a' must be equal at all positions around the coupling cap (8) +/- 0.5 mm (0.0197 in.)
Dimension 'x' must not be more than 1.0 mm (0.0394 in.)
Dimension 'y' must not be more than 1.0 mm (0.0394 in.)
Dimension 'z' must not be more than 0.13 mm (0.0051 in.).

(b) If dimension 'a' is incorrect, do the steps that follow:
1 Temporarily remove access panel 622HB (Ref. AMM TASK 57-41-37-000-006).

Refuel/Defuel Coupling Element Assembly - Location and Detail ** ON A/C NOT FOR ALL

NOTE: The maximum permitted thickness is 4.4 mm (0.1732 in.) and the minimum permitted thickness is 0 mm (0 in.).

.
13 lnstall the lanyard (9) on the attachment lug of the shroud ring (5) with the bolt (10) and the nut (11).
14 TORQUE the nut (11) to between 0.4 and 0.3 m.daN (35.40 and 26.55 lbf.in )

CAUTION: MAKE SURE THAT THE HANDLE OF THE REFUEL COUPLING CAP POINTS AFT WHEN THE CAP IS CLOSED AND LOCKED.

15 lnstall the coupling cap (8) on the coupling (1).
16 Install access panel 622HB (Ref. AMM TASK 57-41-37-400-006).
17 Measure the dimensions 'x', 'y' and 'z' again to make sure that they are correct.
(2) If the coupling cap is attached to the coupling with a chain, continue as follows:
(a) Make sure that these dimensions are correct:

Dimensions and Positions, Right Wing ** ON A/C NOT FOR ALL

Dimension 'a' must be equal at all positions around the coupling cap (28) +/- 0.5 mm (0.0197 in.)
Dimension 'x' must not be more than 1.0 mm (0.0394 in.)
Dimension 'y' must not be more than 1.0 mm (0.0394 in.)
Dimension 'z' must not be more than 0.13 mm (0.0051 in.).

(b) If dimension 'a' is incorrect, do the steps that follow:
1 Temporarily remove access panel 622HB (Ref. AMM TASK 57-41-37-000-006).
2 Remove the coupling cap (28) from the coupling (21).

NOTE: The chain (29) is spring-loaded into a protection sleeve on the coupling cap (28).

NOTE: The maximum permitted thickness is 4.4 mm (0.1732 in.) and the minimum permitted thickness is 0 mm (0 in.).

NOTE: The chain (29) is spring-loaded into a protection sleeve on the coupling cap (28).

12 Install the chain (29) on the attachment tag (30).

CAUTION: MAKE SURE THAT THE HANDLE OF THE REFUEL COUPLING CAP POINTS AFT WHEN THE CAP IS CLOSED AND LOCKED.

13 Install the coupling cap (28) on the coupling (21).
14 Install access panel 622HB (Ref. AMM TASK 57-41-37-400-006).
15 Measure the dimensions 'x', 'y' and 'z' again to make sure that they are correct.

Subtask 28-25-41-860-055-B ** ON A/C NOT FOR ALL

I. Preparation for Test
(1) If the coupling-cap is attached to the coupling with a lanyard, continue as follows:
(a) Refuel the aircraft through the coupling (1) (Ref. AMM TASK 12-11-28-650-003).
(b) Remove the applicable access panel 622HB.
(2) If the coupling-cap is attached to the coupling with a chain, continue as follows:
(a) Refuel the aircraft through the coupling (21) (Ref. AMM TASK 12-11-28-650-003).
(b) Remove the applicable access panel 622HB.

Subtask 28-25-41-790-053-A

J. Test
(1) If the coupling-cap is attached to the coupling with a lanyard:
(a) If you adjusted the laminated shim(s) (3), examine the joint of the element assembly (4) for leaks.
(2) If the coupling-cap is attached to the coupling with a chain:
(a) If you adjusted the laminated shim(s) (23), examine the joint of the element assembly (24) for leaks.

5. Close-up
Subtask 28-25-41-410-061-A ** ON A/C NOT FOR ALL

A. Close Access
(1) Make sure that the work area is clean and clear of tools and other items.
(2) Install the applicable access panel 522HB(622HB).

Subtask 28-25-41-410-061-B ** ON A/C NOT FOR ALL

A. Close Access
(1) Make sure that the work area is clean and clear of tools and other items.
(2) Install the access panel 622HB.

Subtask 28-25-41-865-053-A

B. Remove the safety clip(s) and the tag(s) and close this(these) circuit breaker(s):

PANEL	DESIGNATION	FIN	LOCATION
** ON A/C NOT FOR ALL
49VU	FLIGHT CONTROLS/SLT/CTL AND MONG/SYS1	5CV	B06
** ON A/C NOT FOR ALL
49VU	FLIGHT CONTROLS/SLT/CTL AND MONG/SYS1	5CV	B01
** ON A/C NOT FOR ALL
121VU	FUEL/RFL/DFL/SPLY	2QU	L24
121VU	FUEL/RFL/DFL/XFR/DEFUEL/VALVE	1QU	L23
** ON A/C ALL
121VU	FLIGHT CONTROLS/SLT/CTL/SYS2	7CV	R21
** ON A/C NOT FOR ALL
121VU	FUEL/RFL/DFL/SPLY	2QU	L23
121VU	FUEL/RFL/DFL/XFR/DEFUEL/VALVE	1QU	L22

Subtask 28-25-41-942-056-A

C. Removal of Equipment
(1) Remove the safety barriers.
(2) Remove the access platform(s).
(3) Remove the WARNING NOTICE(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 07:03:16 UTC