Appendix L - Sample Operations and Maintenance Manual.pdf

T.O. 33D4-6-665-1

TECHNICAL MANUAL

OPERATION AND MAINTENANCE INSTRUCTIONS

MAIN ENGINE CONTROL

TEST STAND

3C3972G05

(ATOS)

(GE Aircraft Engines)

F33657-81-C-2006

THIS MANUAL SUPERSEDES APPROVED SPECIAL HANDLING AFMC FORM 252, PROJECT NUMBER 51MOCARGA6Z020R.

DISCLOSURE NOTICE: This information is furnished upon the condition that it will not be released to another nation without the specific authority of the Department of the Air Force of the United States, that it will be used for military purposes only, that individual or corporate rights originating in the information, whether patented or not, will be respected, that the recipient will report promptly to the United States, any known or suspected compromise, and that the information will be provided substantially the same degree of security afforded it by the Department of Defense of the United States. Also, regardless of any other markings on the document, it will not be downgraded or declassified without written approval of the originating United States agency.

DISTRIBUTION STATEMENT D: Distribution authorized to Department of Defense and U.S. DoD contractors only, Critical Technology, 15 January 2006. Refer other requests for this document to 748 CBSG/OM, Tinker AFB, Oklahoma 73145-3031.

WARNING: This document contains technical data whose export is restricted by the Arms Export Control Act (Title 22, U.S.C. 2751 et seq.) or the Export Administration Act of 1979, as amended, Title 50, U.S.C., App. 2401, et seq. Violation of these export-control laws is subject to severe criminal penalties. Dissemination of this document is controlled under DoD Directive 5230.25.

HANDLING AND DESTRUCTION NOTICE: Destroy by any method that will prevent disclosure of contents or reconstruction of the document.

Published under authority of the Secretary of the Air Force

15 MARCH 2003 CHANGE 6 - 1 JUNE 2006

1300626269C Text Box Appendix L

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 DESTROY SUPERSEDED PAGES.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 miniature pointing hands.

Changes to wiring diagrams are indicated by shaded areas.

Dates of issue for original and changed pages are:

Original . . . . . . . . . . . . . . . . . . . . 0 . . . . . . . . . . . . 15 March 2003 Change . . . . . . . . . . . . . . . . . . . . 4 . . . . . . . . . . . . 1 January 2005 Change . . . . . . . . . . . . . . . . . . . . 1 . . . . . . . . . . . . 1 January 2004 Change . . . . . . . . . . . . . . . . . . . . 5 . . . . . . . . . . 15 January 2006 Change . . . . . . . . . . . . . . . . . . . . 2 . . . . . . . . . . . . . . . 1 June 2004 Change . . . . . . . . . . . . . . . . . . . . 6 . . . . . . . . . . . . . . . 1 June 2006 Change . . . . . . . . . . . . . . . . . . . . 3 . . . . . . . . . . . . 1 August 2004

TOTAL NUMBER OF PAGES IN THIS MANUAL IS 254, CONSISTING OF THE FOLLOWING:

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

Title . . . . . . . . . . . . . . . . . . . . . . . . . 6 6-1 - 6-16 . . . . . . . . . . . . . . . . . . . . 0 FP-37 A . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Index 1 - Index 7 . . . . . . . . . . . . . 0 FP-38 Blank i - iii . . . . . . . . . . . . . . . . . . . . . . . . . 6 Index 8 Blank . . . . . . . . . . . . . . . . . 0 FP-39 iv Blank . . . . . . . . . . . . . . . . . . . . . 6 FP-1 . . . . . . . . . . . . . . . . . . . . . . . . . 0 FP-40 Blank v - viii . . . . . . . . . . . . . . . . . . . . . . . 6 FP-2 Blank . . . . . . . . . . . . . . . . . . . 0 FP-41 1-1 - 1-5 . . . . . . . . . . . . . . . . . . . . . 1 FP-3 . . . . . . . . . . . . . . . . . . . . . . . . . 0 FP-42 Blank 1-6 - 1-8 . . . . . . . . . . . . . . . . . . . . . 6 FP-4 Blank . . . . . . . . . . . . . . . . . . . 0 FP-43 1-9 . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 FP-5 . . . . . . . . . . . . . . . . . . . . . . . . . 0 FP-44 Blank 1-10 Blank . . . . . . . . . . . . . . . . . . . 1 FP-6 Blank . . . . . . . . . . . . . . . . . . . 0 FP-45 1-11 - 1-12 Deleted. . . . . . . . . . . . 1 FP-7 . . . . . . . . . . . . . . . . . . . . . . . . . 0 FP-46 Blank 2-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . 0 FP-8 Blank . . . . . . . . . . . . . . . . . . . 0 FP-47 2-2 . . . . . . . . . . . . . . . . . . . . . . . . . . 6 FP-9 . . . . . . . . . . . . . . . . . . . . . . . . . 0 FP-48 Blank 2-3 - 2-4 . . . . . . . . . . . . . . . . . . . . . 0 FP-10 Blank . . . . . . . . . . . . . . . . . . 0 FP-49 3-1 - 3-4 . . . . . . . . . . . . . . . . . . . . . 0 FP-11 . . . . . . . . . . . . . . . . . . . . . . . . 0 FP-50 Blank 4-1 - 4-39 . . . . . . . . . . . . . . . . . . . . 0 FP-12 Blank . . . . . . . . . . . . . . . . . . 0 FP-51 4-40 Blank . . . . . . . . . . . . . . . . . . . 0 FP-13 . . . . . . . . . . . . . . . . . . . . . . . . 0 FP-52 Blank 5-1 - 5-17 . . . . . . . . . . . . . . . . . . . . 0 FP-14 Blank . . . . . . . . . . . . . . . . . . 0 FP-53 5-18 . . . . . . . . . . . . . . . . . . . . . . . . . 5 FP-15 . . . . . . . . . . . . . . . . . . . . . . . . 0 FP-54 Blank 5-19 . . . . . . . . . . . . . . . . . . . . . . . . . 2 FP-16 Blank . . . . . . . . . . . . . . . . . . 0 FP-55 5-20 . . . . . . . . . . . . . . . . . . . . . . . . . 0 FP-17 . . . . . . . . . . . . . . . . . . . . . . . . 0 FP-56 Blank 5-21 - 5-23 . . . . . . . . . . . . . . . . . . 6 FP-18 Blank . . . . . . . . . . . . . . . . . . 0 FP-57 5-24 . . . . . . . . . . . . . . . . . . . . . . . . . 0 FP-19 . . . . . . . . . . . . . . . . . . . . . . . . 0 FP-58 Blank 5-25 . . . . . . . . . . . . . . . . . . . . . . . . . 4 FP-20 Blank . . . . . . . . . . . . . . . . . . 0 FP-59 5-26 - 5-28 . . . . . . . . . . . . . . . . . . . 0 FP-21 . . . . . . . . . . . . . . . . . . . . . . . . 0 FP-60 Blank 5-29 - 5-30 . . . . . . . . . . . . . . . . . . . 2 FP-22 Blank . . . . . . . . . . . . . . . . . . 0 FP-61 5-31 . . . . . . . . . . . . . . . . . . . . . . . . . 0 FP-23 . . . . . . . . . . . . . . . . . . . . . . . . 0 FP-62 Blank 5-32 - 5-33 . . . . . . . . . . . . . . . . . . . 4 FP-24 Blank . . . . . . . . . . . . . . . . . . 0 FP-63 5-34 . . . . . . . . . . . . . . . . . . . . . . . . . 0 FP-25 . . . . . . . . . . . . . . . . . . . . . . . . 0 FP-64 Blank 5-35 . . . . . . . . . . . . . . . . . . . . . . . . . 4 FP-26 Blank . . . . . . . . . . . . . . . . . . 0 FP-65 5-36 . . . . . . . . . . . . . . . . . . . . . . . . . 6 FP-27 . . . . . . . . . . . . . . . . . . . . . . . . 0 FP-66 Blank 5-37 - 5-38 . . . . . . . . . . . . . . . . . . . 0 FP-28 Blank . . . . . . . . . . . . . . . . . . 0 FP-67 5-39 - 5-40 . . . . . . . . . . . . . . . . . . 6 FP-29 . . . . . . . . . . . . . . . . . . . . . . . . 0 FP-68 Blank 5-40.1 Added . . . . . . . . . . . . . . . . 6 FP-30 Blank 5-40.2 Blank . . . . . . . . . . . . . . . . 6 FP-31 5-41 - 5-45 . . . . . . . . . . . . . . . . . . . 0 FP-32 Blank

5-46 . . . . . . . . . . . . . . . . . . . . . . . . . 6 FP-33

5-47 - 5-48 . . . . . . . . . . . . . . . . . . . 0 FP-34 Blank

5-49 - 5-50 . . . . . . . . . . . . . . . . . . 6 FP-35

5-51 - 5-92 . . . . . . . . . . . . . . . . . . . 0 FP-36 Blank

*Zero in this column indicates an original page

A Change 6 USAF

TABLE OF CONTENTS

Chapter Page Chapter Page

LIST OF ILLUSTRATIONS.......................................ii 4.7 Fuel System - Theory of Opera-tion .........................................................4-1

4.28 Variable Stator Vane Actuator

LIST OF TABLES......................................................iii System - Theory of Operation ............4-20

4.29 Vacuum System - Theory of Op-

eration...................................................4-20

FOREWORD ...............................................................v 4.33 Pneumatic System - Theory of Operation..............................................4-20

4.42 Purge System - Theory of Opera-SAFETY SUMMARY...............................................vii tion .......................................................4-21

4.49 Ventilation System - Theory of

Operation..............................................4-221 INTRODUCTION AND GENERAL IN-

4.52 Electrical System - Theory of Op-FORMATION ......................................................1-1 eration...................................................4-22

4.65 Instrumentation Systems - Theory1.1 Introduction.................................................1-1 of Operation .........................................4-241.3 Arrangement ...............................................1-1

4.75 DC Drive System - Theory of Op-1.4 Location of Items .......................................1-1 eration...................................................4-261.5 General Information ...................................1-1

4.76 AC Drive System - Theory of Op-1.6 Test Stand - Purpose ..................................1-1 eration...................................................4-271.7 Significant Item Numbers (Sin) -

4.77 Water System - Theory Of Opera-Description .............................................1-3 tion .......................................................4-271.10 Test Stand - Description.............................1-4

4.81 Safety Features .........................................4-281.17 Leading Particulars .....................................1-4

4.83 Sixteen-Channel Annunciator -1.18 Consumable Materials ................................1-4

Safety Features.....................................4-281.20 Referenced Publications .............................1-4

4.100 Motor Speed Control - Safety1.22 Abbreviations and Symbols .......................1-4

Features ................................................4-29

4.101 Pump and Drive Motor Overload2 SPECIAL TOOLS AND TEST EQUIP-

Protection - Safety Features ................4-29MENT...................................................................2-1

4.102 Emergency Stop Switches - Safety

Features ................................................4-292.1 Introduction.................................................2-1

4.103 Operating Procedures ...............................4-292.3 Special Tools and Test Equipment ............2-1

4.105 Test Stand - Initial Operation ..................4-292.5 Special Tools and Test Equipment

4.106 Test Stand - Startup..................................4-34- Fabrication...........................................2-1

4.111 Test Stand - UUT Testing........................4-372.7 Thermocouple Cable - Fabrication ............2-1

4.112 Test Stand - Shutdown .............................4-372.8 Electrical Interface Unit Cables -

Fabrication .............................................2-1

5 MAINTENANCE INSTRUCTIONS .......................5-1

3 PREPARATION FOR USE AND SHIP-

5.1 Introduction.................................................5-1MENT...................................................................3-1

5.3 Periodic Inspection and Preventive

Maintenance ...........................................5-13.1 Introduction.................................................3-1

5.5 One-Hundred-Seventy-Five-Gal-3.3 Preparation For Use....................................3-1 lon Fuel Tank - Filling ..........................5-23.5 Installation Facilities...................................3-1

5.8 Fluid System - Bleeding.............................5-33.6 Installation Requirements ...........................3-1

5.9 Cleaning ......................................................5-33.7 Unpacking and Locating ............................3-1

5.10 Preliminary Instructions .............................5-33.8 Service Connections ...................................3-1

5.11 Exterior Surfaces - Cleaning......................5-43.13 Preparation for Shipment ...........................3-2

5.12 Interior Surfaces - Cleaning .......................5-4

4 OPERATION INSTRUCTIONS ..............................4-1 5.13 Troubleshooting ..........................................5-4

5.15 Functional Relationship..............................5-4

4.1 Introduction.................................................4-1 5.16 Basis of Test Stand Troubleshoot-

4.3 Controls and Indicators ..............................4-1 ing...........................................................5-4

4.5 Theory of Operation ...................................4-1

Change 6 i

5.17 General Troubleshooting ............................5-5 5.52 Temperature Indicator (649AA) -

5.18 Detailed Troubleshooting Tech- Calibration............................................5-49 niques .....................................................5-5 5.53 Deleted ......................................................5-50

5.19 Repair........................................................5-17 5.54 Electrical Interface Unit (EIU) -

5.21 Disassembly ..............................................5-17 Calibration (Test Stand Serial

5.22 Cleaning ....................................................5-17 Number A9725 and

5.23 Inspection..................................................5-17 BAU00002) ..........................................5-50

5.24 Repair or Replacement .............................5-17 5.61 Electrical Interface Unit (EIU) -

5.25 Assembly...................................................5-18 Calibration (Test Stand Serial

5.26 Alignment .................................................5-18 Number ATT90001 through

5.27 Testing.......................................................5-18 ATT90006 and BAU91002)................5-69

5.28 Turbine Flowmeter - Repair.....................5-18

6 DIAGRAMS..............................................................6-15.32 Calibration.................................................5-19

5.34 Primary Instrumentation ...........................5-19

6.1 Introduction.................................................6-15.35 Secondary Instrumentation .......................5-24

6.3 Significant Item Number (SIN)5.36 Flowmeters - Calibration..........................5-25

Locator ...................................................6-15.40 Micro-Flo 100 Calibration Tables ..........5-30

6.4 Contents ......................................................6-15.43 Micro-Flo 100 - Calibration.....................5-32

5.51 Timer Counter (644CA) - Func-

tional Check .........................................5-49

LIST OF ILLUSTRATIONS

Number Title Page Number Title Page

1-1 Main Engine Control Test Stand.................... 1-2 5-14 Closed Loop Torque Motor Module 2-1 Thermocouple Cable - Fabrication................. 2-2 Wire Wrap Board..................................... 5-64 2-2 Electrical Interface Unit (EIU) Cables - 5-15 Power Lever Angle/Metering Valve

Fabrication.................................................. 2-3 Transducer (PLA/MVT) Module 3-1 Service Connections........................................ 3-4 Wire Wrap Board..................................... 5-66 4-1 Panel Locator ................................................ 4-11 5-16 Control Drive Speed (CDS) Closed 4-2 Panel E .......................................................... 4-12 Loop Controller Wire Wrap Board ......... 5-68 4-3 Panel F - Front View.................................... 4-13 5-17 Electrical Interface Unit (EIU) Assem- 4-4 Panel G - Front View ................................... 4-14 blies - Front View.................................... 5-71 4-5 Panel H.......................................................... 4-15 5-18 Upper Electrical Interface Unit (EIU) 4-6 Service Panel................................................. 4-16 Assembly - Overall View ........................ 5-72 5-1 Turbine Flowmeter Repair............................ 5-20 5-19 Lower Electrical Interface Unit (EIU) 5-2 Typical Micro-Flo 100 and Circuit Assembly - Overall View ........................ 5-73

Board ........................................................ 5-24 5-20 Torque Motor Module - Printed Wire 5-3 Sample Calibration Data Chart .................... 5-26 Board ........................................................ 5-78 5-4 Component Location Diagram - Overall 5-21 Power Level Angle/Metering Valve

View ......................................................... 5-27 (PLA/MVT) Module - Printed Wire 5-5 Typical Flowmeter Curves ........................... 5-28 Board ........................................................ 5-79 5-6 Analog-to-Digital (A/D) Converter Card..... 5-34 5-22 Solenoid Module Board B - Printed 5-7 Temperature Indicator (649AA) - Cali- Wire Board ............................................... 5-81 bration....................................................... 5-51 5-23 Solenoid Module Board A - Printed 5-8 Electrical Interface Unit (EIU) Assem- Wire Board ............................................... 5-82 blies, Front View...................................... 5-52 5-24 Control Drive Speed (CDS) Closed 5-9 Upper Electrical Interface Unit (EIU) Loop Controller - Printed Wire

Assembly .................................................. 5-53 Board ........................................................ 5-83 5-10 Lower Electrical Interface Unit (EIU) 5-25 Meter Module No. 2 - Printed Wire

Assembly .................................................. 5-54 Board ........................................................ 5-85 5-11 Meter Module No. 1 Wire Wrap Board ..... 5-58 5-26 Meter Module No. 1 Board B - Printed 5-12 Electrical Interface Unit (EIU) Calibra- Wire Board ............................................... 5-86 tion Fixture ............................................... 5-60 5-27 Meter Module No. 1 Board A - Printed 5-13 Solenoid Module No. 2 Wire Wrap Wire Board ............................................... 5-87

Board ........................................................ 5-61 ii Change 6

5-28 Closed Loop F110 Torque Motor Mod- FO-2 Hydraulic/Pneumatic Schematic.................FP-43 ule - Printed Wire Board ......................... 5-89 FO-3 Electrical Schematic....................................FP-53

FO-1 Wiring Diagram ............................................FP-1

LIST OF TABLES

Number Title Page Number Title Page

1-1 Units Under Test ............................................... 1-3 5-8 Pressure Transducer Calibration Test 1-2 Leading Particulars............................................ 1-5 Equipment................................................... 5-38 1-3 Consumable Materials....................................... 1-9 5-9 Cascaded Pressure Transducer Systems......... 5-39 1-4 Referenced Publications (DELETED)..................... 5-10 Pressure Indication Calibration Data - 1-5 Symbols and Nonstandard Abbreviations Micro-Flo 100............................................. 5-39

(DELETED)......................................................... 5-11 Pressure Indication Adjustment Data - 2-1 Test Equipment ................................................. 2-1 Micro-Flo 100............................................. 5-40 3-1 Service Connections.......................................... 3-3 5-12 Liquid Flow Indication Calibration Data 4-1 Controls and Indicators ..................................... 4-1 - Micro-Flo 100.......................................... 5-46 4-2 Power Circuit Breakers ................................... 4-22 5-13 Flowmeter Switch Points ................................ 5-47 4-3 Micro-Flo 100 Pressure Transducers.............. 4-24 5-14 Temperature Indicator (649AA) Calibra- 4-4 Micro-Flo 100 Thermocouples ....................... 4-25 tion Data ..................................................... 5-50 4-5 Micro-Flo 100 Flowmeters ............................. 4-25 5-15 Power Supply Voltage Verification................ 5-55 4-6 Temperature Indicator Thermocouples........... 4-25 5-16 Wire Wrap Board Slots and Connectors........ 5-56 4-7 Gages ............................................................... 4-26 5-17 Meter Module No. 1 Voltage Readout........... 5-56 4-8 Sixteen-Channel Annunciator ......................... 4-27 5-18 Closed Loop Controller Configuration, 4-9 Controls - Initial Positions.............................. 4-30 Final Frequency, and Voltage.................... 5-69 4-10 Controls - Shutdown Positions for Main- 5-19 Power Supply Voltage Verification................ 5-74 tenance ........................................................ 4-38 5-20 Power Supply Voltage Locations Listed 5-1 Periodic Inspection............................................ 5-1 By Usage .................................................... 5-75 5-2 Lubrication ........................................................ 5-2 5-21 Printed Wire Board Slots and Connectors ..... 5-76 5-3 Annunciator Troubleshooting ........................... 5-5 5-22 TP14 Voltage .................................................. 5-90 5-4 Test Stand Troubleshooting .............................. 5-8 5-23 Closed Loop Controller Configuration, 5-5 Calibration Data .............................................. 5-21 Final Frequency, and Voltage.................... 5-92 5-6 Flowmeter Calibration Data............................ 5-29 6-1 Significant Item Number (SIN) Locator .......... 6-1 5-7 Temperature Indication Calibration Data

- Micro-Flo 100.......................................... 5-35

Change 6 iii/(iv Blank)