TO 37A-1-101.pdf

TO 37A-1-101

TECHNICAL MANUAL

GENERAL INSTRUCTIONS

USAF

FUEL, WATER, AND LUBRICANT

DISPENSING EQUIPMENT

(ATOS)

F41608-90-D-1819

F41608-93-D-0526

Prepared By: TRI-COR Industries, Inc.

DISTRIBUTION STATEMENT A: Approved for public release; distribution is unlimited. Requests for this document must be referred to AFPA/PTPT, 2430 C Street, Bldg 70, Area B, Wright-Patterson AFB, OH 45433-7632. PA Case Number AFMC 04-404. Submit recommended changes or problems with this Technical Order to AFPA/PTPT.

HANDLING AND DESTRUCTION NOTICE: Handle in compliance with the distribution statement and destroy by any method that will prevent disclosure of the contents or reconstruction of the document.

Published Under Authority of the Secretary of the Air Force

30 SEPTEMBER 2014

INSERT LATEST CHANGED PAGES. DESTROY SUPERSEDED PAGES.

LIST OF EFFECTIVE PAGES

NOTE: The portion of the text affected by the changes is indicated by a vertical line in the outer margins of the page. Changes to illustrations are indicated by shaded or screened areas, or by miniature pointing hands.

Dates of issue for original and changed pages are:

Original . . . . . . . . . . . . . . . . . . . . 0 . . . . . . . 30 September 2014

TOTAL NUMBER OF PAGES IN THIS MANUAL IS 32, CONSISTING OF THE FOLLOWING:

Page *Change Page *Change Page *Change No. No. No. No. No. No.

Title A i - iv 1-1 - 1-3 1-4 Blank 2-1 - 2-3 2-4 Blank 3-1 - 3-2 4-1 - 4-16

*Zero in this column indicates an original page

A USAF

TABLE OF CONTENTS

Chapter Page Chapter Page

LIST OF ILLUSTRATIONS.......................................ii 3.1.3 Returning Fuel to Storage ..........................3-1

3.1.4 Lock Control System..................................3-2

3.1.5 Fuel Dispensing/Transfer Equip-

LIST OF TABLES.......................................................ii ment (As Reflected in AS

924) ........................................................3-2

3.1.6 Collapsible Fabric Fuel Tanks ...................3-2

INTRODUCTION.......................................................iii

4 INSPECTION, TESTING, AND MAIN-

TENANCE ...........................................................4-1

SAFETY SUMMARY................................................iv

4.1 General........................................................4-1

4.1.1 Definitions, Intended Uses and1 FUEL SERVICING NOZZLES ...............................1-1

Storage of Hoses....................................4-1

4.1.2 Aircraft Refueling Hose, EI Stan-1.1 Servicing Nozzles .......................................1-1 dard 1529 Coupler Procedures .............4-31.1.1 Single Point Refueling Nozzles,

4.1.3 Field Repair Procedures forSAE-AS-5877 ........................................1-1

MIL-PRF-370, Type C, 6-Inch1.1.2 Closed Circuit Refueling Nozzle ...............1-1 Hose .......................................................4-31.1.3 Over-the-Wing Nozzles..............................1-1

4.1.4 Local Fabrication of Refueling1.1.4 Nozzle Repair/Testing ................................1-1 Hose Assemblies Using SAE1.1.5 Nozzle Static Bonding................................1-2 AS38404 Couplers.................................4-8

4.1.5 New/Repaired Hose Hydrostatic2 FILTERS AND STRAINERS ..................................2-1 Test.........................................................4-8

4.1.6 Annual Hose Hydrostatic Test .................4-102.1 Filters and Strainers....................................2-1

4.1.7 Hydrostatic Test Frequencies ...................4-112.1.1 Nozzle Strainers..........................................2-1

4.1.8 Soaking and Flushing Procedures ...........4-112.1.2 Line Strainers..............................................2-1

4.1.9 Nozzles, Hoses and2.1.3 Micronic Filters and Filter

Quick-Disconnects (QD’s) ..................4-13Separators...............................................2-1

4.1.10 Water Slug Valves and Automat-2.1.4 Filter Separator Elements ...........................2-1 ic Water Drain Valves.........................4-132.1.5 Differential Pressure Gauges......................2-2

4.1.11 Adjusting Pressure Regulators .................4-142.1.6 Reusable Separator Elements

4.1.12 Meter Validation/Calibration....................4-14(Teflon Screens).....................................2-3

4.1.13 Inspection Data Records...........................4-142.1.7 Filter Separator (F/S) Sumps .....................2-3

4.1.14 Filter Separator Differential Pres-

sure Log (AFTO Form 422)................4-143 FUELS MOBILE/FUELS SUPPORT

4.1.15 Single Point Refueling (SPR)EQUIPMENT (FSE) ............................................3-1

Adaptors ...............................................4-14

4.1.16 Cam and Groove Fittings .........................4-153.1 General........................................................3-1

4.1.17 Differential and Pressure Gauges.............4-153.1.1 Fillstand Bottom Loading...........................3-1

4.1.18 Differential Gauges...................................4-153.1.2 Fillstand Top Loading ................................3-1 i

LIST OF ILLUSTRATIONS

Number Title Page Number Title Page

1-1 Closed Circuit Refueling Equipment 4-2 Mender Hose Connector (J-Connector (Sheet 1 of 2) .......................................... 1-2 Style) Used on MIL-PRF-370, Type

4-1 Hose End Preparation .................................. 4-4 C, 6-Inch Collapsible Hose .................... 4-5 4-3 Couplers ....................................................... 4-9 4-4 MD-3 Over-the-Wing Nozzle Tube .......... 4-12

LIST OF TABLES

Number Title Page Number Title Page

4-1 Refueling Hose .............................................. 4-2 4-2 Ferrule Sizing Chart .................................... 4-16 ii

INTRODUCTION

fuel storage tanks, and other real property, except where1. PURPOSE AND SCOPE.

bulk storage maintenance is contracted out. Base Civil Engineering retains oversight of contracted out locations.1.1 Purpose. This manual provides general instructions for the operation and inspection of fuel dispensing equip- 1.2 Scope.

ment. General procedures for truck operations performed at storage facilities are provided. Inquiries and recommended 1.2.1 Guidance contained in this manual are applicable to changes to this technical order should be directed to the Air fuel and dispensing equipment defined as mobile. This Force Petroleum Agency (AFPA). manual provides maintenance and inspection guidance for certain components critical for fuel quality of mobile sys-

1.1.1 AFLCMC/WNZ has engineering responsibility tems where operation and maintenance is performed by (mechanical design, placement of components, standard base fuels personnel and/or vehicle maintenance personnel.

operation of pumping system, etc.) for NSC 2320, Truck and Truck Tractors and NSC 4930, FORCE Equipment. 1.2.2 Where guidance concerning fuel quality in this tech- Technical Orders (TO) for NSC 2320 and 4930 take nical order conflict with provisions contained in technical precedence over this TO. manuals associated with fuel and equipment, the guidance in this technical order take precedence. TO 00-25-172 will

1.1.2 Base Civil Engineering has maintenance responsi- be complied with during all refueling/defueling operations.

bility for the truck fillstands, installed fuel hydrant systems, iii

SAFETY SUMMARY

1. WARNING AND CAUTION STATEMENTS. 4. FINGER RINGS/JEWELRY.

WARNING and CAUTION statements have been strategi- Finger rings have caused many serious injuries. Remove cally placed throughout this text prior to operating or rings, watches, and other metallic objects during all mainte-maintenance procedures, practices, or conditions consid- nance activity.

ered essential to the protection of personnel (WARNING) or equipment and property (CAUTION). A WARNING 5. COMPRESSED AIR.

and CAUTION will apply each time the related step is repeated. Prior to starting any task, the WARNINGs or Use of compressed air can create an environment of pro- CAUTIONs included in the text for the task will be pelled particles. Do not direct air streams towards self or reviewed and understood. other personnel. Air pressure shall be reduced to less than

30 psig and used with effective chip guarding and personal

2. DEFINITIONS. protective equipment.

6. DANGEROUS PRESSURE.

WARNING

Care must be taken during testing to ensure that all test connections are proper and tight. All system components

Highlights operating procedures or practices must be compatible with pressure applied. Personnel must which, if not correctly followed, could result in be protected by a safety shield or located at a distance personnel injury or loss of life. sufficient to prevent injury.

7. PERSONAL PROTECTIVE EQUIPMENT (PPE).CAUTION

If unique local conditions make compliance with the pro- Highlights operating procedures or practices tective clothing or other occupational health requirements which, if not strictly observed, could result in specified in this manual unnecessary or impractical, obtain damage to or destruction of equipment and/or an evaluation of the operation from the Bio-Environmental property. Engineer. The Bio-Environmental Engineer and Base

Safety Office will determine the required precautions.

NOTE

8. CLEANERS/CHEMICALS.

An essential operating or maintenance proce-dure, condition, or statement, which must be Some cleaners and chemicals have adverse effects on skin, highlighted. eyes, and the respiratory tract. Observe manufacturers’

WARNING labels; Material Safety Data Sheets (MSDS) instructions for proper handling, storage, and disposal; andShall and Indicate mandatory requirements. Will is current safety directives. Use only in authorized areas.Will also used to express a declaration of pur- Unless otherwise indicated in the text, use as described inpose.

this TO should not result in any immediate health concerns.Should Indicates a preferred method of accomplish- Consult the local Bio-Environmental Engineer and Basement.

Safety Office for specific protection equipment and ventila-

May Indicates an acceptable, optional, or suggest- tion requirements.

ed means of accomplishment.

9. CONFINED SPACE/CRAWLSPACES.

3. GENERAL PRECAUTIONS.

Personnel that work within a confined space(s) that: by The following are general safety precautions that are not design has limited openings for entry and exit, has unfavor-related to any specific procedures and, therefore, do not able natural ventilation, not intended primarily for human appear elsewhere in this technical manual. These are gen- occupancy, or contains other recognized safety hazards eral safety precautions and instructions that people must shall comply with the requirements of AFI 91-203, Air understand and apply during many phases of operation and Force Consolidated Occupational Safety Instruction. An maintenance to ensure personal safety and health, and the AF Form 1024, CONFINED SPACES ENTRY PERMIT protection of Air Force property. will be processed with the local Safety, Health, and Fire

Prevention offices prior to entering the space.

iv

CHAPTER 1

FUEL SERVICING NOZZLES

1.1.1.4 An automatic vacuum breaker valve will be1.1 SERVICING NOZZLES.

installed on any SPR nozzles that are used on defueling unit hoses or on other fuel servicing vehicle/equipment hoses1.1.1 Single Point Refueling Nozzles, that are used during defueling. The automatic vacuumSAE-AS-5877. Refer to Table 4-1 of TO 00-25-172 for a breaker valve is used to prevent damage to the hose and list of approved Single Point Refueling (SPR) nozzles and aircraft fuel system.

authorized applications.

1.1.2 Closed Circuit Refueling Nozzle.

CAUTION 1.1.2.1 A special refueling nozzle is available for refuel-ing H-1 helicopters that have been modified to permit Closed Circuit Refueling (CCR). This nozzle, NSNThe 45-degree D-1 nozzle is acceptable for 4930-01-194-2625, is the normal refueling method at themost SPR servicing operations, especially for home station of the H-1 helicopters. The capability existsfuselage servicing. The straight throat D-2 noz-for the CCR nozzle receptacle on the helicopter to swingzle is only for underwing fuel servicing appli-away. This provision permits routine over-the-wing refuel-cations and must not be used otherwise unless ing at locations not equipped with the CCR nozzle.deemed mission essential. Solid state panto-graphs (no hoses) utilized with fuselage refuel- 1.1.2.2 A locally manufactured adapter is required toing operations equipped with D-2 nozzles are mate the CCR nozzle to the dry break coupler (seeapproved for use without mission essential Figure 1-1).determination. Inappropriate utilization of the single point nozzles can and has caused undue 1.1.3 Over-the-Wing Nozzles.

stress damage to aircraft SPR adaptors, fuel spills, broken nozzles and components, and 1.1.3.1 Type MD-3, 2-inch female NPT inlet, NSN other safety related problems. 4930-01-022-7901.

1.1.1.1 Mission essential determination shall be made by 1.1.3.2 1 ⁄1 2-inch female NPT inlet, NSN the ranking individual on shift in the Fuels Service Center 4930-01-293-4472.

(FSC) and shall be documented on the control log in the Fuels Manager Defense (FMD) system by the on duty fuels 1.1.3.3 Nozzles may be equipped with nozzle supports controller. This information will include but not be limited installed on the servicing tube. The support is to protect the to the crew chief’s name, the controller’s name on duty in aircraft skin and be installed and adjusted to protect the the MOCC, and a brief description of why the straight bottom of shallow fuel tanks.

throat D-2 was deemed mission essential.

1.1.3.4 Over-the-wing nozzles shall be held by personnel

1.1.1.2 The D-1 nozzle has a 45-degree inlet throat, while at all times while servicing aircraft and not allowed to the D-2 nozzle has a straight throat. Both nozzles incorpo- remain in the tank open port or rest on the aircraft surface rate a 360-degree swivel feature. The D-3 universal inlet without support.

nozzle coupling has the capability to perform as a straight

1.1.4 Nozzle Repair/Testing.throat or 45-degree nozzle depending on the positioning of the swivels. The universal nozzle can be used for both

1.1.4.1 Repair kits and other parts for nozzles should beunderwing and fuselage fuel servicing. The SPR nozzles obtained from the manufacturer’s distributor. Using activi-are designed to connect a refueling/defueling unit to an ties are encouraged to procure necessary parts and locallyaircraft at a single point receptacle.

repair the nozzles. Repair instructions and parts breakdown

1.1.1.3 The refueling supervisor will ensure the refueling are contained in the end item technical manuals.

nozzle is securely locked to the aircraft by attempting to

1.1.4.2 New or overhauled nozzles shall be operationallyremove the nozzle with the nozzle crank handle in the open pressure checked and flushed prior to being used forposition prior to pressurizing the hose. If the nozzle can be aircraft servicing. Defective nozzles will be removed fromremoved from the aircraft with the crank handle open, it service and repaired or replaced.will immediately be removed from service. If the nozzle leaks while attached to the SPR adapter and the crank handle is open, the fueling operation shall be terminated until a serviceable nozzle is installed. The leaking nozzle shall be removed from service and turned in for repair.

1-1

1.1.5 Nozzle Static Bonding. Over-the-wing nozzles 5935-00-572-5174. Cable length may vary according to activity requirements.used for aviation fuel must be equipped with a static bonding cable, NSN 4010-00-575-6234, and plug, NSN

P0304203

SCALE FULL

PLAN

1/2 HARD BRASS

1/4 IN. R

3.00 IN.

2.375 IN.

SECTION

0.270

0.655

0.385

STANDARD 2 IN. PIPE THREAD

1/16 x 45˚

CHAMFER

1.870 IN.60˚ 1.907 IN. R

2.

IN

Figure 1-1. Closed Circuit Refueling Equipment (Sheet 1 of 2)

1-2

P9402537

ADAPTER FITTING

LEGEND

1. Screw (6 ea.) 5. Adapter Fitting (1 ea.)

2. Washer (6 ea.) 6. Gasket (1 ea.)

3. Nuts (6 ea.) 7. Male Coupling (1 ea.)

4. Nozzle (1 ea.)

Figure 1-1. Closed Circuit Refueling Equipment (Sheet 2)

1-3/(1-4 blank)

CHAPTER 2

FILTERS AND STRAINERS

2.1.3 Micronic Filters and Filter Separators.2.1 FILTERS AND STRAINERS.

2.1.3.1 Micronic filters are equipped with elements2.1.1 Nozzle Strainers.

designed to remove solids from fuel. Elements of this type are not effective for the removal of free water. Currently2.1.1.1 All aircraft fuel servicing nozzles will be equipped the FORCE R-20 is the only mobile AF equipment withwith a nozzle strainer. Nozzles used in fillstand operations micronic elements and will be changed in accordance withwill follow strainer mesh guidance in TO 37-1-1. For the following criteria:mobile refueling equipment, nozzles will be equipped with a strainer having a minimum of 60-mesh. If final filtration

a. When the adjusted differential pressure exceeds 15 psiis more than 120 feet from the nozzle, the nozzle shall be across the element in accordance with TO 42B-1-1.equipped with a 100-mesh strainer.

b. When the elements have been in service for 362.1.1.2 Nozzle strainers shall be removed or reversed on months.all designated defuel units.

c. When vessel performance is unsatisfactory or ques-tionable.CAUTION

2.1.3.2 Filter separators are designed with two stages to

extract solids and water from fuel during fuel movement.The ball valve is not meant to be an on/off The first stage consists of fiberglass which removes solidsvalve and could cause severe damage if moved and coalesces free water. The second stage cartridges arewhile pressure/flow is on the hose.

made with media such as Teflon coated mesh screen, silicone treated pleated paper or synthetic media. This stage2.1.1.3 Approved nozzle strainer ball valves are listed in permits throughput of fuel but forms a barrier to cause theTO 00-25-172. This valve is placed between the hose end fallout of water. Water must be drained from filterand the nozzle in place of the quick-disconnect. It allows separators daily when used.the strainer to be switched from refuel to defuel position with a side-mounted handle (the removable handle is not authorized for future procurement in USAF applications). 2.1.4 Filter Separator Elements.

The side inspection port allows the operator to inspect the strainer when converting the refueling unit from refuel to defuel and back as well as perform the monthly inspection CAUTION without opening the system. If the strainer ball valve is procured, it must be obtained with the glass observation

Wearing protective gloves or leaving the plasticcover option, not the blank cover option.

around the element during installation of new

2.1.1.4 Nozzle strainers shall be inspected and, if neces- filters will reduce possible contamination of the sary, cleaned on refuelers used for one time defuels prior to outer surface to ensure elements coalesce water the next fuel issue. as designed. Care must be taken to prevent damage to new elements during installation

2.1.1.5 The ball valve strainer must be inspected every (i.e. dropping, end cap damage, tearing of the time the ball valve position is switched, and cleaned as sock material, proper torque, etc.).

necessary. This strainer is the last line of protection for preventing solid contaminates from entering an aircraft or NOTE the refueling vehicle components. If the strainer is not inspected and cleaned, damage to the aircraft fuel sys- Shelf life for filter elements in original packag-tems/refueling vehicle components and fuel spills may ing and in a controlled environment may be occur. stored for five years (60 months) from the date of manufacture. Elements that have exceeded2.1.2 Line Strainers. Line strainers are installed on the 60-month criteria shall not be used.

mobile fuel servicing equipment. All line strainers shall be cleaned and inspected in accordance with applicable TO or 2.1.4.1 Contact AFPA Technical Assistance Division, more often if flow becomes restricted. DSN 785-8070 for the most recent qualified filter elements for replacement.

2-1

b. When the elements have been in service for 36 months.CAUTION

c. When vessel performance is unsatisfactory or ques- All filter element mounting plastic thread tionable.

adapters shall be replaced with aluminum

2.1.4.5 New elements shall be installed dry after thethread adapters. Filter separators with plastic interior of the vessel has been cleaned.thread adapters are subject to failure and equip-ment damage if not replaced.

WARNING2.1.4.2 Filter elements installed in mobile/FSE equipment filter separators will be changed in accordance with the following standard criteria (this standard criteria takes Static induced ignition of fuel is possible if a precedence over all other published data to include manu- filter separator vessel is filled at customary facturer’s recommendation or vessel data plate): flow rates, resulting in an explosion.

a. When the adjusted differential pressure exceeds 15 psi 2.1.4.6 After installing new elements, fill the filter across the filter separator. separator at the lowest attainable flow rate.

b. When the elements have been in service for 36 2.1.4.7 Vessels will be marked (stenciled, painted, or months. stickers) with letters in black, 3/4 or one inch high, to identify the next change date listed as MM/YY (example:c. When vessel performance is unsatisfactory or ques- Mar 15 for March 2015) for the filter element, what typetionable.

filter elements are installed (part number from the element end cap), and the maximum allowable Differential PressureNOTE (DP) as identified in TO 42B-1-1.

Filters used in mobile refueling equipment des- 2.1.4.8 Vessels used for monitor elements only will have ignated as +100 grade fuels shall be EI 1581, the elements removed and the vessel marked ‘‘Monitors 5th Edition, M100 qualified. Once equipment is Removed - Vessel Empty’’.

no longer in +100 grade fuels use, filters do not need to be changed until one of the previous 2.1.5 Differential Pressure Gauges. Solids buildup on conditions exist. filter elements is indicated by a corresponding higher differential pressure reading. Sudden reduction in differen-

2.1.4.3 Elements installed in mobile refueling equipment tial pressure indicates elements may have ruptured.

designated as +100 grade fuel, will be changed in accor-dance with the following standard criteria (this standard

NOTEcriteria takes precedence over all other published data to include manufacturer’s recommendation or vessel data

The three-way valve installed on piston typeplate):

differential pressure gauges is not meant to be used as a direct pressure gauge when pushed toa. +100 fuel grade filters shall be approved API/IP 1581, determine upstream pressure readings and5th Edition, M100 qualified.

should not be used as such.

b. When the adjusted differential pressure exceeds 15 psi

2.1.5.1 Differential pressure readings will be recorded onacross the filter separator.

the AFTO Form 422 in accordance with TO 42B-1-1.

c. When the elements have been in service for 36

2.1.5.2 Periodic calibration of the Gammon Gauge ismonths.

unnecessary because the graduated scale is made to match

d. When vessel performance is unsatisfactory or ques- the characteristics of the spring. The spring is at its “free, tionable. full length” when there is zero differential pressure; the top of the piston is in the “zero band”. However, if there is no

2.1.4.4 Filter elements installed in FSE filter separators differential pressure imposed on the Gammon Gauge and used to receive, transfer, truck fillstand, etc. (not used as the piston does not return to zero, either the spring has final filtration to an A/C) will be changed in accordance failed and should be replaced, or the piston is sticking in with the following standard criteria (this standard criteria the glass cylinder and requires repair (see Paragraph 4.1.18 takes precedence over all other published data to include for gauge inspection).

manufacturer’s recommendation or vessel data plate):

2.1.5.3 The piston type Differential Pressure (DP) gauge

a. When the adjusted differential pressure exceeds 20 psi can be equipped with a peak hold feature. This feature will across the filter separator.

2-2 register the maximum DP that is measured during an b. Each separator should be checked by pouring water operation, automatically locking the piston so the operator (not spraying or allowing the water to fall more will have that information without actually having watched than 3 inches) over the entire screen surface. The the gauge at the time the reading was recorded. After the water should bead and roll off the screen. If the reading has been seen, the operator releases the piston by water does not bead, but seeps into the screen, the turning the knob. separator must be cleaned again. Hot water may be used with a soft bristle brush or rag and rinsed with clean fuel and retested. If the screen fails a second2.1.6 Reusable Separator Elements (Teflon time, the separator should be replaced.Screens).

c. After separators pass the water test, rinse separators with clean fuel and set aside until readyCAUTION for reinstallation.

Do not touch teflon screen. 2.1.7 Filter Separator (F/S) Sumps.

These elements may surround the filter elements or may be in a separate section of the vessel. The Teflon elements will WARNING be inspected and cleaned each time the filter elements are changed.

When performing sumping procedures, always

2.1.6.1 Cleaning Process. wear proper PPE. Failure to comply may result in personal injury.

a. After removing separators from the filter/separator vessel, set separator in a bucket of clean fuel and Filter separator sumps will be drained of sediment and wipe the inside and outside down with a soft bristle water daily when used or prior to the first servicing of the brush or clean rag. day. A minimum of one gallon shall be continuously drained before taking a visual sample. Follow TO 42B-1-1

b. Not applicable. for sample requirements and draining instructions. Place the equipment in a pumping mode that will establish a

2.1.6.2 Inspecting. minimum pressure of 10 to 20 psi in the F/S vessel.

a. Hold separators by the end caps and inspect entire screen surface for any nicks or cuts. Any flaws smaller than 1/8 inch may be repaired with a fuel resistant epoxy. Inspect end caps for damage.

2-3/(2-4 blank)

CHAPTER 3

FUELS MOBILE/FUELS SUPPORT EQUIPMENT (FSE)

d. Connect the fillstand hose/pantograph arm to the3.1 GENERAL.

bottom loader ensuring the nozzle is securely locked in place.This chapter provides general operating procedures for filling/emptying refueling units at storage facilities and

e. Test the high level shutoff system, if equipped, atprocedures for lock control systems. Personnel performing the beginning of each filling operation. If the testtransfer operations will be proficiency evaluated and quali-fails, remove the vehicle from service immediatelyfied in accordance with AFI 23-201. Safety precautions and notify RFM. Units with a non-operational highwill be followed in accordance with applicable Air Force level shutoff system will only be used when mis-Consolidated Occupational Safety Instructions.

sion essential at which time a person must be placed on top of the unit upwind to prevent

3.1.1 Fillstand Bottom Loading. overfilling.

NOTE

CAUTION

Personnel shall not be stationed on top of a refueler if the unit is equipped with an opera-Refueling vehicle Bottom Load Override Con-tional high level shutoff system.trols are never to be used during truck filling operations. If a filling operation stops prema-

f. Upon completion of the operation, disconnect theturely, a visual inspection of tank quantity will nozzle and stow the fillstand hose/pantograph arm.be taken. When a filling operation stops prema-turely, refer to locally developed fillstand fill- g. Complete required accountable documents in ing checklist for troubleshooting. accordance with DLA Energy Policy and Interim

Guidance.This method is the primary method of filling Air Force refueling equipment. h. Perform a safety walk around inspection of the refueler and remove the bonding cable/umbilicala. Position the vehicle to prevent stress on compo-cord.nents during connection and fuel transfer.

3.1.2 Fillstand Top Loading. A waiver request will beb. Engage the parking brake and turn off vehicle submitted and approved by AFPA Current Operations.engine.

Waivers must be coordinated with local Safety Office prior

c. Bond the vehicle to the fillstand prior to making to submission.

any nozzle connection. This will equalize any static

3.1.3 Returning Fuel to Storage. This operation isbuild-up between the truck and fillstand.

performed the same as an issue to an aircraft.

(1) Refueling units that require the SPR nozzle to be connected before the Intellicheck is ener- a. Position the vehicle to prevent stress on equipment gized, will be bonded to the fillstand first using components during fuel transfer.

the vehicle bonding cable.

b. Bond the unit to the storage system.

NOTE

c. Connect the issue hose to the off-loading header.

Fillstands equipped with Scully controls utilize d. Transfer fuel to the storage system.

an umbilical cord with the bonding cable included. This cable must be attached to the e. Upon completion, disconnect and stow the hose.

truck before the fillstand will operate.

f. Complete accountable documents in accordance

(2) Refueling units that energize the Intellicheck with DLA Energy Policy and Interim Guidance.

from the cab (movement of a switch) require the

g. Perform a safety walk around inspection and dis-umbilical to be attached before the nozzle con-connect the bonding cable.nection. It will take the place of the vehicle bonding cable connection.

3-1

3.1.4 Lock Control System. Lock control systems are maintained in a complete serviceable condition by accom-used to prevent the inadvertent issue of product. plishing the required calibrations, inspections, and tests on components and systems. Shelf life for filter elements

3.1.4.1 Units in aviation service. stored in original packaging and in a controlled environ-ment may be stored for five years (60 months) from the

a. Bases which use more than one grade of aviation fuel date of manufacture. Filter elements (wet or dry) installed will have locking control systems on their refueling in WRM-stored FORCE/FSE must be replaced after 36 units. months. It is permissible to store filter separator vessels without elements installed. The filter separator vessel mustb. Defuel units will have a lock control system.

be clearly identified as NO FILTER ELEMENTS INSTALLED. In addition, the equipment records mustc. Units on QC hold will be locked.

reflect the necessity to install the filter elements prior to deployment or activation of fuel equipment. The system3.1.4.2 Units not in aviation service will be locked in may be periodically pressure checked without filter ele-accordance with AFI 23-201.

ments installed.

3.1.4.3 All vehicles/trailers containing reclaimed or

3.1.6 Collapsible Fabric Fuel Tanks. For all guidancerecoverable fuel will be locked.

pertaining to fuel bladders, refer to TO 37A12-15-1.

3.1.5 Fuel Dispensing/Transfer Equipment (As

Reflected in AS 924). All fuel servicing systems will be

3-2

CHAPTER 4

INSPECTION, TESTING, AND MAINTENANCE

4.1.1.5 Temperature, humidity, ozone, sunlight, oils, sol-4.1 GENERAL.

vents, corrosive liquids and fumes, insects, rodents, and radioactive materials can affect hose products. The appro-The data in Table 4-1 is a guide for use by field activities.

priate method for storing hose depends on its size (diameter

4.1.1 Definitions, Intended Uses and Storage of and length), the quantity to be stored, and the way it is packaged. Hoses should not be piled or stacked to such anHoses. The following definitions apply to the words used extent that the weight of the stack creates distortions on thein Table 4-1:

lengths stored at the bottom. Whenever feasible, rubber hose products should be stored in their original shippingSoft A hose evacuated to a collapsed containers. Hoses, shipped in coils or bales, should beposition for easy storage.

stored so that the coils are in a horizontal plane. Storage

Semi-Hard A non-reinforced hose that is pli- areas should be relatively cool and dark, free of dampness able but is not required to col- and mildew. Items should be stored on a first-in, first-out lapse for storage. basis, since an unusually long shelf life could deteriorate

Hard A wire or cord helix reinforced certain rubber products. Exposure to direct or reflected hose. sunlight, even through windows, should be avoided.

Uncovered hoses should not be stored under fluorescent or

4.1.1.1 Only hoses identified in Table 4-1 shall be used mercury lamps, which generate light waves harmful to on fuel servicing equipment. rubber.

4.1.1.2 Semi-hard hose should not be evacuated flat for 4.1.1.6 Hose shelf/storage life varies with storage loca-ease of movement or storage. Evacuation of semi-hard hose tion, climatic conditions, hose storage conditions, and the will cause undue stress to the interior lining of the hose specific type of hose.

causing premature failure. If semi-hard hose is to be stored for any length of time and the fuel needs to be removed to 4.1.1.7 All hoses in storage or in service shall have a alleviate the excess weight, the fuel can be evacuated out maximum hose life of 15 years from the manufactured date.

and at the same time air replaced (by operating a vacuum Hoses stored for 10 years, shall be visually inspected breaker on the nozzle) to maintain the shape of the hose. annually and hydrostatically tested prior to putting the hose When hose is bent at too sharp of an angle it may kink and in service.

shorten the effective hose life. Any such kinking or evacu-

4.1.1.7.1 Hoses that have been removed from their origi-ating flat is not an acceptable or safe practice (refer to nal packing should be stored as close to requirementsTable 4-1).

outlined in Paragraph 4.1.1.5 above, so no damage can be

4.1.1.3 Only EI Standard 1529, Grade 2 (300 psi WP), sustained to the hose (i.e. no kinks, end caps in place, flat Type C hose will be used for hot refueling, hot Concurrent coils, no direct sunlight).

Servicing Operation (CSO) supporting Combat Sortie Gen-

4.1.1.7.2 If hoses are installed on equipment ineration (CSG) and hot/rapid defueling operations. Hose WRM/FORCE/FSE inventory, an inspection should beused for hot/rapid defuel operations shall be procured accomplished during the operation inspection of the equip-locally with the length determined by specific need. Nor-ment. This inspection should include, but not limited to,mally the standard 2 1/2'' x 60′ R-11 hose is adequate but extending the hose completely and visually inspecting forlonger can be procured if needed. The hose shall have an cuts, kinks, bubbles, and slippage of couplers.AF approved single point nozzle (according to TO

00-25-172, Table 4-1) on each end to attach to the aircraft

4.1.1.8 Vehicle modification requests will be initiated byand bottom loader. The hose shall be tested in accordance the Fuels Vehicle Control Officer (VCO) and routed towith Table 4-1 under the Purpose column for hot/rapid Vehicle Maintenance for approval. Aircraft servicing hosesdefueling.

not required for servicing aircraft such as R-12 platform hoses may be removed and stored IAW Paragraph 4.1.1.54.1.1.4 Hose conforming to Specification above. Annotate removal of the platform hoses and identifyMIL-DTL-27516 and MIL-PRF-370, Types A, B, and D, the storage location in the permanent portion of the vehicleshall be used only for suction and low-pressure dispensing historical record.applications. The MIL-PRF-370, Type C, collapsible hose, can be used for high-pressure discharge transfer lines (refer to Table 4-1).

4-1

4-2

T ab le

-1

R ef ue lin g H os e

P re ss u re A n n u al

H yd ro st at ic

(p si g

H o se E n d

I te m In

-S to ra g e T es t1

H o se I

D W o rk in g

P ro o f

B u rs t

T yp e S p ec if ic at io n A p p lic at io n

P u rp o se E xt

C ri te ri a F re q u en cy In ch es

2'

So ft

M

IL

-D T

L -2

R -9

H os e R ee l an d

D is ch ar ge V is ua l Pr io r to H yd ra nt H os e

C ar t In sp ec tio n

In st al la tio n

4'

C ol la ps ib le

M

IL

-D T

L -3

R -1

4/ R

-1 8/

R -1

9/ D is ch ar ge

V is ua l

M fg

C er tif ie d 6'

T yp e

C R

-2 0/

R -2

1/ R

-2

In sp ec tio n or

P ri or t o In st al la tio n C ol la ps ib le P/

N A

E

-2 Fo rw ar d A re a

M an i-

FA

R P

V is ua l

Pr io r to

I ni tia l

2' fo ld

FA

M

C ar t In sp ec tio n

U se

R et es t A nn ua lly C ol la ps ib le P/

N A ng us

H os e

FA

M C ar t

FA

R

P V is ua l Pr io r to I ni tia l 2'

In sp ec tio n

U se

R et es t A nn ua lly 1.

Se m i- H ar d

M

IL

-D T

L -6

5, R -2

0, O ve r-th e-

Su ct io n an d

V is ua l

M fg

C er tif ie d

C ol la ps i- C la ss

I

T yp e I

W in g an d H os e

D is ch ar ge In sp ec tio n or P ri or t o

1.

5' bl e C ar ts

In st al la tio n

2'

2.

5'

3'

4'

Se m i-

H ar d E

I

G ra de

Su pp or t

E qu ip m en t

D ef ue l an d

V is ua l

M fg

C er tif ie d 1'

.5

R -1

1/ R

-1 4/

R -2

0/ R ef ue l In sp ec tio n or P ri or t o

C -3

H yd ra nt

In st al la tio n

Se rv ic in g V eh ic le s an d

E qu ip m en t

Se m i- H ar d

E I

G ra de

Su pp or t E qu ip m en t H ot R ef ue l, V is ua l M fg C er tif ie d

2'

R -1

1/ R

-1 4/

R -2

0/ H ot /R ap id

In sp ec tio n or

P ri or t o C

-3 a nd

H yd ra nt

D ef ue l, an d

In st al la tio n, Se rv ic in g V eh ic le s

H ot

C

SO

S up

R et es t A nn ua l-an d E qu ip m en t po rt in g C

SG

ly

1'

.5

H ar d/

Se m i- M

IL

-P

R F-

0, R -1

4/ R

-1 8/

R -2

1/ R

-2

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V is ua l

M fg

C er tif ie d H ar d

T yp es A

B

D L ow P re ss ur e

In sp ec tio n or

P ri or t o 2'

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In st al la tio n

2.

5'

3'

A ll

H ar d/

Se m i- M

IL

-D

T L

-2

H os e C ar ts

H y- In le t

H os e V is ua l M fg C er tif ie d

H ar d E

I

G ra de dr an t Se rv ic in g

V e-

In sp ec tio n or

P ri or t o 2' hi cl es

In st al la tio n

1'

.5

H ar d

M

IL

-D T

L -2

PM

U

-2 an d

Su ct io n an d

V is ua l

M fg

C er tif ie d A

B

FD

S L ow P re ss ur e

In sp ec tio n or

P ri or t o 2'

D is ch ar ge

In st al la tio n

4'

1 M an uf ac tu re r (M fg hy dr os ta tic t es t ce rt if ic at io n is v al id u ni tl ex pi ra tio n da te

A ft er t ha t da te ho se m us t be r et es te d pr io r to u se

4.1.2 Aircraft Refueling Hose, EI Standard 1529 4.1.3 Field Repair Procedures for MIL-PRF-370, Type C, 6-Inch Hose.Coupler Procedures. EI Standard 1529, Grade 2 (300 psi WP) refueling hose will be recoupled using couplers designed for use on aircraft fueling hose. The coupler will NOTE incorporate the features and specifications by design as depicted by the two-piece internally expanded coupler (see Procedures for installation of the FORCE type Figure 4-3). Couplers shall meet the requirement of the female coupling half, P/N 60CHD2-33446, latest edition of EI 1529 unless otherwise specified by the male coupling half, P/N 60EHD2-33446 and purchaser. When a hose in service is to be fitted with a new hose clamp set, P/N 60HD2-33446 can be coupling, the following should be observed: found in the FORCE TO 37A9-3-5-61.

4.1.3.1 The purpose of these procedures are meant to

WARNING provide in-the-field repair for a 6'' mender clamp as applied to fuel hose (MIL-PRF-370, Type C). The procedures and torque specifications in Paragraph 4.1.3.2 shall be used for

Accuracy of hose measurement is critical to the replacement of mender clamp hose end (female and proper ferrule selection and security of the hose male) connectors. Splicing of damaged hose will be con-end coupler. Improper ferrule selection could ducted using the procedures and torque specifications in result in coupler/hose separation causing a fuel Paragraph 4.1.3.3.

spill and fire hazard.

WARNING

CAUTION

Hose separations from the coupler can result in When assembling hoses to couplers, do not catastrophic fuel spills, fires, personal injury, alter the outer surface of the hose. Shaving the death, and/or cause great damage to the envi-outer surface or covering to allow easy fit of ronment. Any indication of hose slippage the ferrule will weaken the connection and SHALL be cause to immediately place the allow the hose to separate from the coupler system out of service until hose repair is com-when pressure is applied. plete. Once bolts have been torqued to the proper specification after custom made hose NOTE lengths have been made, the bolts SHALL

NOT be re-torqued to check tightness and the Brass ferrules manufactured by Couple-Up Inc. bolts SHALL have a line painted or marked on will not be installed on EI 1529 hose. Brass the bolt head. Over-torquing of bolts could ferrules by Couple-Up Inc. have a history of cause the bolts to snap or stretch, weakening stress cracking or splitting as much as 2 years the clamp and causing hose separation from the after installation and hydrostatic testing. Stain- coupler. Under-torquing the bolts will not allow less steel (300 series) ferrules manufactured by the clamp to effectively grip the hose/coupler Couple-Up are acceptable. assembly and could lead to hose separation from the coupler. The following repair proce-

4.1.2.1 Recoupling must be done by a hose manufacturer, dures must be performed in a well-ventilated distributor, or user having a formal written procedure and a area and the proper PPE must be worn. Fuel training program on recoupling. products can cause injury to the skin, eyes, and the respiratory tract.4.1.2.2 The hose assembly must be indelibly marked or fitted with a durable label, or the coupling itself punched to 4.1.3.2 In preparation to repair/replace the MIL-PRF-370, show the coupler’s name and location, and the date of Type C, 6-inch collapsible hose end, inspect area of hose recoupling. adjacent to the coupler for damage. If damage of the hose is identified, the section of hose must be removed to a point4.1.2.3 The recoupling hose assembly must satisfy hydro-where the hose is acceptable for use.static testing requirements with Paragraph 4.1.5 before being returned to service. a. Remove pressure from the hose. Drain hose com-pletely or clamp hose shut about three feet from end of hose.

4-3

b. Using a measuring device, mark a line approxi-mately 1.75'' from the end of the hose to identify WARNING the location of the cut to be made. Locate the ground wire(s) and measure 0.25'' longer from that

Once bolts have been torqued to the propermark away from the damaged section of hose.

specification after custom made hose lengthsUsing a hose knife or other sharp cutting tool, slice have been made, the bolts SHALL have a linethe hose lengthwise along the ground wire(s) being painted or marked on the bolt head.careful not to damage the wire(s). With a pair of Over-torquing of bolts could cause the bolts topliers, pull the ground wire(s) out of the protective snap or stretch, weakening the clamp and caus-covering making sure they are pulled back beyond ing hose separation from the coupler.the mark for the hose cut. Using a hose knife or Under-torquing the bolts will not allow theother sharp cutting tool, cut the hose square to the clamp to effectively grip the hose/couplerhose axis (lengthwise). This should expose approx-assembly and could lead to hose separationimately 2'' of the imbedded ground wire(s) around from the coupler.the hose diameter. The ends of the exposed ground wire(s) should be square of each other if more than one wire is imbedded (see Figure 4-1).

CAUTION

CAUTION

The tightening of each bolt on the specific mender clamp will need to be completed sev-eral times at each level (10 ft lbs, 20 ft lbs, 30 ftScrews and retaining ring are stainless steel lbs, etc.) to ensure all three bolts are at the(not black). The ring is in the clamp groove.

specific torque before moving to the next levelThe Hydrasearch connector has flat O-rings. Be of the torque sequence. A torque wrench capa-careful not to damage these during installation.

ble of adjustment above the final recommended

c. Using the appropriate tool that fits the bolts for torque of each connector is required.

each mender connector clamps, set gaps between clamp segments to approximately ⁄1 4'' (see NOTE Figure 4-2).

Be certain to torque the specific mender con-

d. Pre-position the mender clamp segments over the nector to the recommended value. J-Connector hose tube approximately one foot from the cut end (50 ft lbs); Hydrasearch connector (30 ft lbs).

of the hose.

g. Use a torque wrench with the appropriate adaptor to tighten each screw equally (starting at 10 ft lbs

CAUTION and increasing in 10 ft lb increments) being careful not to bottom out the segment pieces. The gaps should be equal and less than 1/8'' each.Verify there is approximately 1 inch of ground wire(s) exposed on the end of the cut hose. This is required to ensure contact with the mender connector (barb) for grounding safety of the hose.

e. Fold the ground wire(s) inside the cut end of the hose. Insert the mender connector (barb) into the hose. The hose should cover all of the barbs on the connector. The ground wire(s) should be between the hose and the barbs of the mender connector (see Figure 4-2).

f. Position the mender clamp approximately ⁄1 2'' from the end of the hose square to the hose axis (length-wise). Snug clamp screws equally on each segment by hand using the appropriate tool. Gaps should be equal and approximately ⁄1 4'' each. P0900016

2nd C ut

1 3/4 in ch es

2 inches

Extend wire(s) away from hose and fold inside between the hose and connector.

Figure 4-1. Hose End Preparation

4-4

P0405834

1 2 1

6-1/2

Index Number Qty Part Name

1 2 J-clamp

2 1 J-connector

Figure 4-2. Mender Hose Connector (J-Connector Style) Used on MIL-PRF-370, Type C, 6-Inch Collapsible Hose

4-5

h. Once bolts have been torqued to the proper specifi- a. Remove pressure from the hose. Drain hose com-cation, the bolts SHALL have a line painted or pletely or clamp hose shut about three feet on both marked on the bolt head. sides of damaged section of hose.

i. Verify continuity of hose ground wire(s) through NOTE repaired hose length by using an ohm meter and placing a lead on each hose end connector. If hose On damages greater than ⁄1 4'', remove at least fails continuity check, remove mender clamp and one foot of hose on both sides of the damaged repeat Steps e through g until ground continuity is area. This will ensure enough room for the achieved. replacement section of hose to be clamped over mender connectors and that the mender connec-j. Using a can of spray paint, spray a two-inch white tors are not jammed into each other causingband around the cut hose end adjacent to the possible leaks.mender connector (barb) in order to facilitate inspection of the hose for slippage. Write the data b. Using a measuring device, mark a line square to of installation on the hose. the hose axis approximately 1.75'' from the end of the hose to identify the location of the cut to bek. Hydrostatically test the repaired hose following made. Locate the ground wire(s) and measure 0.25''Paragraph 4.1.5 in this TO. If the hydrostatic longer from that mark (away from the damagedtesting equipment is not available, and the hose is section of hose) (see Figure 4-1). Using a hoseto be put into service immediately following the knife or other sharp cutting tool, slice the hoserepair, perform Steps l and m.

lengthwise along the ground wire(s) being careful not to damage the wire(s). With a pair of pliers,l. If clamps were used to shut off fuel to the damaged pull the ground wire(s) out of the protective cover-area of the hose, remove clamps, slowly fill and ing making sure they are pulled back beyond thepressurize the hose. If the hose was drained, recon-mark for the hose cut. Using a hose knife or othernect hose to pump and slowly pressurize hose.

sharp cutting tool, cut the hose square to the hoseMonitor the hose repair for 30 minutes during flow axis (lengthwise). This should expose approxi-and observe gap between hose ends for slippage.

mately 2'' of the imbedded ground wire(s) around the hose diameter. The ends of the exposed groundm. Perform a visual leak check on repaired hose. If wire(s) should be square of each other if more thanrepair fails check, repeat procedure steps as one wire is imbedded.required until leak is no longer noted.

NOTE

CAUTION

There are currently two approved mender con-nectors for the MIL-PRF-370 6-inch collapsible Screws and retaining ring are stainless steel hose not associated with the FORCE connec- (not black). The ring is in the clamp groove.

tors used to repair damaged hose with holes ⁄1 4'' The Hydrasearch connector has flat O-rings. Be or greater in size. They are the J-Connector careful not to damage these during installation.

(Figure 4-2) and Hydrasearch Connector (NSN 4730-01-389-7706). The procedures for repair- c. Using the appropriate tool that fits the bolts for ing the hose using either of these connectors is each mender connector clamps, set gaps between the same unless specifically specified (i.e. 50 clamp segments to approximately ⁄1 4'' (see ft/lbs for the J-Connector, 30 ft/lbs for the Figure 4-2).

Hydrasearch connector, etc.).

d. Pre-position the mender clamp segments on both

4.1.3.3 In preparation to repair the MIL-PRF-370, Type sides of hose tube approximately one foot from the C, 6-inch collapsible hose, inspect area of hose that has cut end of the hose. (If damage is larger than ⁄1 4'', been damaged and determine if hole is ⁄1 4'' wide or greater. pre-position mender clamp segments as far back as If damage is larger than ⁄1 4'', the removal of at least one foot necessary on the replacement section of hose mak-on each side of the damaged section will be required. A ing sure not to interfere with installation of the replacement length equal to the removed section of hose mender connectors).

and a second repair kit may be required. Verify all required items in this procedure are available before making initial cut into the hose for repair. Perform the following steps for hose damage less than ⁄1 4'' wide.

4-6 snap or stretch, weakening the clamp and caus-ing hose separation from the coupler.CAUTION Under-torquing the bolts will not allow the clamp to effectively grip the hose/coupler

Verify there is approximately 2'' of ground assembly and could lead to hose separation wire(s) exposed on each end of the hose cut. from the coupler.

This is required to ensure contact with the mender connector (barb) for grounding safety

CAUTIONof the hose.

e. On one end of the hose that was…