C-130_FuelControl-1__TestInstruction.pdf.pdf

TO 2G-GTCP85-43-9

SWP 006 01

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Replace section “9. Testing” in TO 2G-GTCP85-43-9 SWP 006 01 in its entirety with the following:

9. TESTING, Model Number: 3882810-1

NOTE

Refer to T.M. SE-876-03-1053 for operation and maintenance of 281600-7-1/281600-7-1-P1 test stand assembly.

a. Depreservation (If necessary)

CAUTION

Do not contaminate the calibration fluid in the test stand with preservation fluid removed from fuel control unit.

WARNING

Fuel and calibration fluid (43-44A) are toxic to the eyes, skin, and respiratory tract. Eye and skin protection required. Use only in a well-ventilated area.

(1) Plug all ports in fuel system except fuel-pump inlet and fuel-control discharge. Apply 24 to 28 Vdc to solenoid to open solenoid. Supply a source of fuel or calibration fluid to the fuel-pump inlet at a pressure of 5 to 25 psig. Operate pump at 200 to 500 rpm until all oil has been removed from fuel control unit and discharge stream contains pure calibration fluid.

b. Preparation for Test

(1) Use 281600-7-1/281600-7-1-P1 test stand assembly or provide a test setup using items (Figure 18, 1 through 19) that are capable of running the unit to the input parameters and output measurements specified in Table 6, using instrumentation capable of meeting the accuracy requirements of Table 4, and also capable of producing the required back-pressures of Table 5.

(2) Service test stand assembly using calibration fluid (43-44A).

(3) Install fuel control unit with filter element down, on mounting pad of test stand assembly, checking mesh of fuel control unit drive shaft with drive shaft splines of test stand assembly.

Ensure input shaft will turn in a clockwise direction when viewing from input shaft end. Attach the fuel control unit to the test stand using all 4 mounting holes in the fuel pump housing (Figure 13, 94).

(4) Hook up fuel control unit, as required, to meet parameters specified in Tables 4, 5, and 6.

(5) Maintain a complete and accurate record of test run.

(6) Refer to paragraph “10 Troubleshooting” for aid in correcting problems encountered during testing.

c. Fuel Leakage Check

Throughout the entire testing procedure there shall be no fuel leaking from the acceleration port, any adjusting screw seals, or from mating joints – at any time. If fuel leakage rates in the input drive shaft cavity or out of the drain port exceed one drop in 5 minutes, reject the unit.

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Type of

Measurement Application

Test Requirement

(Actual)

Gage Requirement

(Minimum)

Accuracy

(Minimum)

Angular Velocity Input Driveshaft Speed 400-4265 rpm 0-5000 rpm ±2 rpm

Inlet Air Pressure (Acceleration Limiter Valve, Air Inlet) 11-48 psig 0-60 psig ±2 psig

Nozzle Discharge Air Pressure (Back Pressure) 11-48 psig 0-60 psig ±2 psig

Fuel Inlet Pressure 1-26 psig 0-30 psig ±1 psig

Nozzle Discharge Pressure 15-325 psig 0-575 psig ±5 psig

Pump Discharge Pressure 57-63 psig 0-75 psig ±2 psig

Fuel Flow Rate Nozzle Fuel Flow Rate 0-600 pph 0-900 pph ±2 pph

Air Pressure

Fuel Pressure

Table 4. Instrument Range and Accuracy Requirements for Fuel Control Unit, Model No. 3882810-1

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d. General Test Instructions

(1) Testing sequences, input and output limits, and run parameters are contained in Table 6. Refer to Table 6 for all references to data point values.

For each operating sequence the input parameters shall be applied to the fuel control unit in the following order: fuel inlet pressure, input driveshaft speed, inlet air pressure.

(2) All testing operations shall be accomplished sequentially in the numerical order they appear within the testing instructions. It is not necessary to de-energize the fuel control unit between testing sequences. If a test section needs to be repeated, start at the previous sections final condition.

(3) All references to pump discharge pressure shall be interpreted to apply to those pressures coming out of the governor section of the fuel control unit. All references to nozzle discharge pressure shall be interpreted to apply to those pressures coming out of the electric solenoid.

(4) The electric solenoid is a normally closed device. Apply 24 to 28 Vdc to open, or energize, the solenoid. See Figure 18, Detail A for solenoid wiring diagram.

(5) For all testing sequences, the nozzle discharge pressure shall be the sum of the nozzle back pressure curve and additional pressure equal to the air pressure applied to the acceleration limiter valve. This may be accomplished via an air controlled regulator connected to the air input and situated after the nozzle discharge simulator or by adding additional back pressure equal to air input to the back pressure curve at each testing sequence.

e. Test Procedures

NOTE

Maintain a complete and accurate record of test run. Table 6, or equivalent automated test sheet, may be used for documentation.

(1) Air Leakage Check, Acceleration Limiter Valve

(a) Install a pressure gage, with a minimum range of 0 to 60 psig, onto the acceleration limiter drain port. Apply detergent compound (43-34) to all areas where air pressure is contained. Adjust the input parameters to the settings specified in data point 1.a. If any increasing pressure is read on the gage at the drain port or if any air leaks are detected with the detergent compound, reject the unit. Upon completion, remove the pressure gage and wipe off residual detergent.

WARNING

When disconnecting fuel lines between the fuel control unit and test stand always break connection at the side furthest away from the flow source. Ensure free end of fuel line is pointed in a safe direction before running fuel control unit.

(2) Purging Run (Priming Operation)

(a) Disconnect test stand end of the fuel line attached between the governor cap and the test stand. Point free end of fuel line in a safe direction and adjust the input parameters to the settings specified in data point 2.a.

(b) Run unit for the time allotted then proceed to data point 2.b. After the fuel flowing through the line begins to discharge in a steady stream reduce driveshaft speed to zero

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rpm then reduce the fuel inlet pressure to zero psig. Reconnect the free end of the fuel line back onto the test stand and proceed to paragraph 9.e.(3).

NOTE

Run-In Schedule (Pump Break-In) is required only when bushings, gears, or housings have been replaced.

CAUTION

Open nozzle bypass valve and shut off valve before each increase in input driveshaft speed to prevent over-pressurization and damage to the fuel control unit.

(3) Run-In Schedule (Pump Break-In)

(a) Remove the filter cap (Figure 13, 11) and filter element (Figure 13, 13) from the fuel control unit. Install filter plug assembly (288276-1) and filter plug cover (288277-1) to fuel control unit. Disconnect fuel-out line from outlet port on fuel solenoid valve and connect to outlet port on filter plug cover. Install cap on solenoid valve to prevent unintentional discharge.

(b)The nozzle discharge pressure shall be adjusted via the nozzle bypass valve and shut off valve. Sequentially operate the fuel control unit at each data point, 3.a through 3.e. If the fuel flow is less than the required value for data point 3.e, reject the unit.

(c) Decrease input driveshaft speed and inlet air pressure to zero. Decrease fuel inlet pressure to zero psig. Open nozzle bypass valve and shut off valve. Remove previously installed cap from solenoid valve. Remove fuel line from outlet port on filter plug cover and reinstall on solenoid valve. Remove filter plug assembly and filter plug cover.

Reinstall filter element (13) and filter cap (11). Torque filter cap (11) to 100-110 inch-pounds.

(4) Acceleration Limiter Valve Cracking Pressure/ Crack Pressure Sensitivity

(a) Disconnect air line from acceleration limiter and leave acceleration limiter port uncapped.

(b) Beginning with the fuel solenoid valve in the closed position, adjust the input parameters to the settings specified in data point 4.a. Cycle (energize/de-energize) solenoid and measure pump discharge pressure. Loosen nut (Figure 13, 30) and adjust the acceleration limiter adjusting screw (35) to obtain the fuel nozzle pressure (crack pressure) specified.

Tighten nut (30). Recheck two times by cycling (energize/de-energize) fuel solenoid valve twice.

(c) If cracking pressure is unstable, loosen screws (Figure 13, 32) and tap cover (38) gently until pressure stabilizes. Tighten screws (32) and perform step 9.e.(4)(b).

(d) If acceleration limiter still will not adjust within specified data points perform the following:

1 Disconnect the hose linking the acceleration limiter to governor.

2 Apply 10 ±1 psig air to the governor only. Set input parameters to settings specified in data point 4.a. If the crack pressure is higher with air to the governor than the pressure recorded in 9.e.(4)(a) perform the following.

a Shut down the test stand.

b Remove the governor head and add washers (Figure 13, 61) between the governor spring (Figure 13, 60) and the ceramic sleeve (95). Maximum of three washers.

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c Reassemble the governor.

d Recheck the crack pressure without air to the governor.

e Reconnect the line linking acceleration limiter to governor.

3 Perform step 9.e.(4)(b).

(e) Sequentially operate the fuel control unit at each subsequent data point within this step

(data points 4.b through 4.e). For each fuel inlet pressure setting recheck the crack pressure two times by cycling fuel solenoid valve twice. Ensure the pump discharge pressures for all data points is within limits. Reject the unit if it is unable to reliably meet data point requirements.

(f) Reconnect air line to acceleration limiter.

(5) Governor Set Point

(a) Adjust the input parameters to the settings specified in data point 5.a.

1 Adjust the high speed governor adjustment screw (Figure 18, 18)as necessary, to obtain the required fuel flow (clockwise to increase flow).

2 Operate fuel control for time specified in data point 5.a.

3 Readjust high speed governor adjustment screw (87) if required.

(b) Adjust the input parameters to the settings specified in data point 5.b.

(c) Subtract the fuel flow rate data point 5.b from fuel flow rate data point 5.a; record on data point 5.c. The value must be greater than 50 pph. If the value is not greater than 50 pph, adjust screw (Figure 18, 17) to achieve a drop of 50 pph or more. Recheck governor set point by performing 9.e.(5)(a).

(d) Adjust the input parameters to the settings specified in data point 5.d.

1 Adjust the low speed governor adjustment screw (Figure 18, 19), as necessary, to obtain the required fuel flow (clockwise to increase flow).

2 Operate fuel control for time specified in data point 5.d.

3 Readjust low speed governor adjustment screw (19) as required.

(e) Adjust the input parameters to the settings specified in data point 5.e.

1 Apply 24 to 28 Vdc to energize (open) the two-speed solenoid; record data.

2 Subtract the fuel flow rate data point 5.d from fuel flow rate data point 5.c.; record on data point 5.f.

(f) Adjustment of the two-speed delay valve may be required to meet the fuel flow requirements of steps 9.e.(5)(a) through 9.e.(5)(e). If the low-speed adjustment cannot be adjusted down enough to meet the required fuel flow rates, remove washers from the governor as required (reference steps 9.e.(4)(c) 3 a through 9.e.(4)(c) 3 e). If washers are removed recheck acceleration limiter crack pressure in accordance with step 9.e.(4) and recheck governor set point.

NOTE:

The governor spring may be changed to one of the optional springs to obtain required droop. Reference

2G-GTCP85-44, Spring (Figure 50, 60).

(6) Fuel Flow

(a) Adjust the input parameters to the settings in data point 6.a; record Nozzle Discharge

Pressure.

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(b) Adjust the input parameters to the settings in data point 6.b; record Nozzle Discharge

Pressure.

(c) If the fuel flow minimum in data point 6.b cannot be met it can be decreased by performing the following (adding shims will decrease minimum fuel flow):

1 Shut down the test stand.

2 Remove the governor head and add shims (2G-GTCP85-44, Figure 50, 95) between governor bearing (Figure 13, 96) and the ceramic slide valve (95).

3 Reassemble the governor.

4 Recheck the fuel flow minimum by performing step 9.e.(6)(c).

(d) Reject the unit if it is unable to meet data point requirements for fuel flow.

(7) Speed Droop and Hysteresis

NOTE:

Steps requiring adjustment of RPM to achieve specified fuel flow parameters must adjust the RPM to reach max flow point, and continue increasing RPM to achieve specified fuel flow.

NOTE:

Do not to overshoot the speed settings for the increasing and decreasing of data points.

(a) Adjust the input parameters to the settings specified in data point 7.a.

(b) Decrease speed to obtain fuel flow rates as specified in data points 7.b and 7.e; record data at each point.

(c) Increase speed to obtain fuel flow rates as specified in data points 7.f and 7.i; record data at each point.

(d) Calculate speed droop and hysteresis as instructed in data points 7.j through 7.m.

(8) Pump Performance

(a) Adjust the input parameters to the settings in data points 8.a. The nozzle discharge pressure shall be adjusted via the nozzle bypass valve and shut off valve.

(b) If the fuel flow is less than that specified in data point 8.a, check the pressure drop across the fuel solenoid valve (Figure 18, 10). If the pressure exceeds 74 psi, reject the fuel solenoid valve.

(c) If the pressure drop across the fuel solenoid valve is less than 74 psi, realign fuel pump gears as follows:

1 Adjust the rpm between 500-800.

2 Adjust the fuel inlet pressure to 25±1 psig.

3 Adjust the inlet air pressure to 47±1 psig.

4 Adjust the nozzle bypass valve and shut off valve to achieve a nozzle discharge pressure of 60±2 psig.

5 Loosen nuts (Figure 9, 113) 1/8 to ¼ turn and adjust housing (123) to obtain an increase in pump discharge pressure. Ensure pump components are seated.

6 Tighten nuts (113) and torque to 60 to 65 in-lbs.

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7 Recheck pump by performing step 9.e.(8)(a).

8 Changes to pump discharge pressure will affect governor set point and gain. Re-perform step 9.e.(5).

(9) Repeatability and Nozzle Pressure Fluctuation

NOTE:

Steps requiring adjustment of RPM to achieve specified fuel flow parameters must adjust the RPM to reach max flow point, and continue increasing RPM to achieve specified fuel flow.

(a) Sequentially operate the fuel control unit at the input parameters listed in data points

9.a through 9.g. Record all data. Check repeatability and nozzle pressure fluctuations as instructed. Reject the unit if it is unable to meet data point requirements.

(10) Governor Set-Point Recheck

(a) Adjust the fuel control unit to the operating parameters listed in data point 10.a. If necessary, readjust the high speed governor set point and repeat this step.

(b) Adjust the fuel control unit to the operating parameters and run for time listed in data point 10.b. If necessary, readjust the low speed governor set point and repeat

9.e.(10)(a) and this step.

(c) Lockwire high speed governor adjustment screw (Figure 13, 87) and low speed governor adjustment screw (74) using lockwire (43-51). Repeat steps 9.e.(10)(a) and 9.e.(10)(b).

Reject if the unit is unable to meet the data point requirements.

(11) Acceleration Limiter Valve Cracking Pressure Recheck

(a) Beginning with the fuel solenoid valve in the closed position, set the fuel control unit to the operating parameters listed in data point 11.a. Recheck crack pressure two times by cycling (energizing/de-energizing) fuel solenoid valve twice. If necessary, reset crack pressure as required and repeat this step.

(b) Lockwire screws (Figure 13, 32) using lockwire (43-51). Repeat step 9.e.(11)(a) after acceleration limiter valve has been lockwired. Reject the unit if it is unable to meet the data point requirements.

(12) Input Shaft Seal Leakage Check

(a) Adjust the fuel control unit to the operating parameters and run for time specified in data point 12.a. The leakage rate from the fuel control input drive shaft seal into the drain cavity shall not exceed on drop in 5 minutes. Reject the unit if it is unable to meet the data point requirements.

(13) Fuel Filter Inspection and Leak Check

(a) Adjust all inputs to zero.

(b) Remove and inspect fuel filter.

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(c) If no evidence of foreign particles is found, reinstall the filter. If foreign particles are found covering between 1% and 10% of the filter surface area, install new filter. If foreign particles are found covering greater than 10% of the filter surface area, replace filter, and repeat test. If foreign particles are found covering greater than 10% of the filter surface area after the repeated test, reject unit.

(d) Adjust the fuel control unit to the operating parameters listed in data point 12.a and operate for 1 minute. Inspect fuel filter cap for external leakage; none is permissible.

f. Preservation

(1) Adjust input drive shaft speed to zero.

(2) Adjust inlet air and fuel inlet pressures to zero.

(3) Shut off fuel, air and electrical power supplies.

(4) Disconnect electrical connector from fuel solenoid valve.

(5) Provide a suitable drain container.

(6) Disconnect fuel lines from fuel control unit. Drain line into drain container.

(7) Disconnect air lines to fuel control unit.

(8) Perform Preservation in accordance with paragraph 11.

g. Post Test

(1) Lockwire filter cap (Figure 13, 11), plugs (Figure 16, 16, 26, and 28), and screws (Figure 13, 57), using lockwire (43-51).

(2) Remove fuel control unit from test setup. Drain fluids into drain container.

NOTE

Do not use tape to cover openings

(3) Install protector cover over drive shaft (Figure 13, 3) and secure to unit.

(4) Plug all openings and place fuel control unit in a dust and waterproof container.

TO 2G‐GTCP85‐43‐9

Results

T.O.

Paragraph Number Required Actual Required Actual Required Actual Required Actual Required Actual Required Actual

9.e.(1) 1 a Close 5 ± 1 40 ± 1 PASS / FAIL a Close Close Open 3/4 ± 1/4 20 ± 5 0 0 b Close Close Open 20 ± 5 800 ± 50 0 a Open 10 ± 1 25 ± 1 500 ± 100 0 25 ± 10 Record b Open 5 ± 1 25 ± 1 1500 ± 100 0 65 ± 25 Record c Open 5 ± 1 25 ± 1 2500 ± 100 0 165 ± 25 Record d Open 5 ± 1 25 ± 1 3500 ± 100 0 275 ± 50 Record e Open 5 ± 1 25 ± 1 3930 ± 100 0 300 ± 10 ≥ 600 a Open/Close Close Open 25 ± 1 860 ± 10 0 60 ± 1 0 b Open/Close Close Open 1 +1/ ‐0 860 ± 10 0 60 ± 3 0 c Open/Close Close Open 10 ± 1 860 ± 10 0 60 ± 3 0 d Open/Close Close Open 15 ± 1 860 ± 10 0 60 ± 3 0 e Open/Close Close Open 20 ± 1 860 ± 10 0 60 ± 3 0

No Load Condition a Open Close Open 5 ± 1 25 ± 1 4260 ± 2 47 ± 1 Record 133 ± 2

Two Speed Delay Adjustment b Open Close Close 25 ± 1 4260 ± 2 47 ± 1 Record Record

Reduced Flow Check c 5.a ‐ 5.b

(must be greater than 50)

Reduced Speed Setpoint d Open Close Close 5 ± 1 25 ± 1 2823 ± 2 12 ± 1 Record 60‐65

Energize Two‐Speed Head e Open Close Open 25 ± 1 2823 ± 2 12 ± 1 Record Record

Increased Flow Check f 5.e ‐ 5.d

(must be greater than 50)

9.e.(4) Acceleration Limiter Valve Cracking Pressure/ Crack Pressure Sensitivity

4 PASS / FAIL

9.e.(5) Governor Adjustment

5 PASS / FAIL

9.e.(3) Run‐in Schedule (Pump break‐in) 3 Close

Adjustable

(Used to adjust nozzle discharge pressure)

PASS / FAIL

For each testing sequence circle the applicable result.

Test Sequence Data Point

Air Leakage Check, Acceleration Limiter Valve

9.e.(2) Purging Run (Priming Operation) 2 PASS / FAIL

Fuel Inlet Pressure (psig)

Input Driveshaft Speed

(RPM)

Inlet Air Pressure (Acceleration Limiter Valve, Air Inlet)

(psig)

Nozzle Discharge Pressure (Back Pressure)

(psig) Pump Discharge Pressure

(psig) Fuel Flow Rate

(pph) Applicable T.O.(s): 2G‐GTCP85‐43‐9 Fuel

Solenoid Position (open/ close)

Nozzle/ Atomizer

Bypass Valve (open/ close)

Two Speed Solenoid Valve (open/ close)

Time Required (minutes)

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Table 6 ‐ Testing Operation(s) and Data Point(s) (Page 1 of 3) SN: Date: Operator:

Part Number, Fuel Control Unit: 3882810‐1 Machine Settings and Duration Inputs Outputs

Results

T.O.

Paragraph Number Required Actual Required Actual Required Actual Required Actual Required Actual Required Actual

Maximum a Open Close Open 25 ± 1 4070 ± 10 47 ± 1 Record 325 min

Minimum b Open Close Close 25 ± 1 3700 ± 5 29 ± 3 Record 45 ± 2 a Open Close Open 25 ± 1 Record 47 ± 1 Record 113 ± 2 b Open Close Open 25 ± 1 Record 47 ± 1 Record 133 ± 2 c Open Close Open 25 ± 1 Record 47 ± 1 Record 183 ± 2 d Open Close Open 25 ± 1 Record 47 ± 1 Record 213 ± 2 e Open Close Open 25 ± 1 Record 47 ± 1 Record 300 ± 2 f Open Close Open 25 ± 1 Record 47 ± 1 Record 213 ± 2 g Open Close Open 25 ± 1 Record 47 ± 1 Record 183 ± 2 h Open Close Open 25 ± 1 Record 47 ± 1 Record 133 ± 2 i Open Close Open 25 ± 1 Record 47 ± 1 Record 113 ± 2 j 55‐85

7.a minus 7.i k 15 max

7.c minus 7.g l 15 max

7.d minus 7.f m 15 max

9.e.(8) 8 a Open

Adjustable (Used to adjust nozzle discharge pressure)

Open 25 ± 1 3905 ± 50 47 ± 1 300 ± 10 510 min PASS / FAILPump Performance

9.e.(6) Fuel Flow 6 PASS / FAIL

9.e.(7)

Speed Droop and Hysteresis

7 PASS / FAIL

Record Speed Droop (7.a minus 7.d)

Record Hysteresis

For each testing sequence circle the applicable result.

Test Sequence Data Point

Fuel Inlet Pressure (psig)

Input Driveshaft Speed

(RPM)

Inlet Air Pressure (Acceleration Limiter Valve, Air Inlet)

(psig)

Nozzle Discharge Pressure (Back Pressure)

(psig) Pump Discharge Pressure

(psig) Fuel Flow Rate

(pph) Applicable T.O.(s): 2G‐GTCP85‐43‐9 Fuel

Solenoid Position (open/ close)

Nozzle/ Atomizer

Bypass Valve (open/ close)

Two Speed Solenoid Valve (open/ close)

Time Required (minutes)

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Table 6 ‐ Testing Operation(s) and Data Point(s) (Page 2 of 3) SN: Date: Operator:

Results

T.O.

Paragraph Number Required Actual Required Actual Required Actual Required Actual Required Actual Required Actual

Set‐Point a Open Close Open 25 ± 1 Record

(4260 ref) 47 ± 1 Record 133 ± 2

Speed Decrease b Open Close Open 25 ± 1 3930 ± 5 47 ± 1 Record

Return to Set‐Point c Open Close Open 25 ± 1 Record 47 ± 1 Record 133 ± 2

Ramp Down d Close Open Open 25 ± 1 0 0 0 0

Shutdown e Close Open Open 0 0 0 0 0

Repeatability Check f Open Close Open 25 ± 1 Record 47 ± 1 Record 133 ± 2

Maximum difference between data points: 9.a, 9.c, and 9.f g 10 max 14 max

No Load Set‐Point a Open Close Open 25 ± 1 4260 ± 2 47 ± 1 Record 133 ± 4

Reduced Speed Setpoint b Open Close Close 5 ± 1 25 ± 1 2823 ± 2 12 ± 1 Record 65 ± 5

9.e.(11) 11 a Open/Close Close Open 25 ± 1 860 ± 10 0 60 ± 1 0 PASS / FAIL

9.e.(12) 12 a Close Close Open 5 +1/ ‐0 1 +1/ ‐0 4260 ± 5 40 ± 1 PASS / FAIL

Acceleration Limiter Valve Cracking Pressure ‐ Recheck

Input Shaft Seal Leakage Check

9.e.(9)

Repeatability and Nozzle Pressure Fluctuation

9 PASS / FAIL

9.e.(10) Governor Set‐ Point Recheck

10 PASS / FAIL

For each testing sequence circle the applicable result.

Test Sequence Data Point

Fuel Inlet Pressure (psig)

Input Driveshaft Speed

(RPM)

Inlet Air Pressure (Acceleration Limiter Valve, Air Inlet)

(psig)

Nozzle Discharge Pressure (Back Pressure)

(psig) Pump Discharge Pressure

(psig) Fuel Flow Rate

(pph) Applicable T.O.(s): 2G‐GTCP85‐43‐9 Fuel

Solenoid Position (open/ close)

Nozzle/ Atomizer

Bypass Valve (open/ close)

Two Speed Solenoid Valve (open/ close)

Time Required (minutes)

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Table 6 ‐ Testing Operation(s) and Data Point(s) (Page 3 of 3) SN: Date: Operator:

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