C-130_FuelControl-101__TestInstruction.pdf.pdf

TO 2G-GTC85-33-9

WP 005 00

OO-MAN-2015-00148

Insert Table 2 before Section “8. Testing” and after paragraph 7.5.k.

OO-MAN-2015-00148

Replace Section “8. Testing” in TO 2G-GTC-33-9 WP 005 00 in its entirety with the following:

8. TESTING

NOTE

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

8.1 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 (33-23) are toxic to the eyes, skin, and respiratory tract. Eye and skin protection required. Use only in a well-ventilated area.

a. 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.

8.2 Preparation for Test

a. Fuel control unit, part No. 371688-101, must be tested with a fuel solenoid valve attached. All units to be tested that do not already have an attached fuel solenoid valve shall be tested with a slave unit (p/n: 692545-2 or 75327).

b. Use 281600-7-1/281600-7-1-P1 test stand assembly or provide a test setup using items (Figure 19, 1 through 16) and capable of running the unit to the input parameters and output measurements specified in Table 5, using instrumentation capable of meeting the accuracy requirements of Table 3, and also capable of producing the required back-pressures of Table 4.

c. Service test stand assembly using calibration fluid (33-23).

d. 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 14, 100).

e. Hook up fuel control unit, as required, to meet parameters specified in Tables 3, 4, and 5.

f. Maintain a complete and accurate record of test run.

g. Refer to Troubleshooting section, paragraph 9, for aid in correcting problems encountered during testing.

Figure 20. DELETED

8.3 Fuel Leakage Check

a. 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.

8.4 General Test Instructions

a. Testing sequences, input and output limits, and run parameters are contained in Table 5. Refer to table 5 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.

b. 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.

c. 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 fuel solenoid valve.

Type of

Measurement Application

Test Requirement

(Actual)

Gage Requirement

(Minimum)

Accuracy

(Minimum)

Angular Velocity Input Driveshaft Speed 400-4605 rpm 0-5500 rpm ±2 rpm

Inlet Air Pressure (Acceleration Limiter Valve, Air Inlet) 34-51 psig 0-60 psig ±2 psig

Nozzle Discharge Air Pressure (Back Pressure) 34-51 psig 0-60 psig ±2 psig

Fuel Inlet Pressure 1-25 psig 0-30 psig ±1 psig

Nozzle Discharge Pressure 15-550 psig 0-600 psig ±5 psig

Pump Discharge Pressure 59-61 psig 0-75 psig ±2 psig

Fuel Flow Rate Nozzle Fuel Flow Rate 0-500 pph 0-900 pph ±2 pph

Air Pressure

Fuel Pressure

Table 3. Instrument Range and Accuracy Requirements for Fuel Control Unit, Model No. 371688-101

OO-MAN-2015-00148

d. The electric solenoid is a normally closed device. Apply 24 to 28 Vdc to open, or energize, the solenoid. See Figure 19, Detail A for solenoid wiring diagram.

e. For all testing sequences, the fuel 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.

8.5 Test Procedures

Maintain a complete and accurate record of test run. Table 5, or equivalent automated test sheet, may be used for documentation.

a. Air Leakage Check, Acceleration Limiter Valve

(1) Install a pressure gage, with a minimum range of 0 to 60 psig, onto the acceleration limiter drain port. Apply detergent compound (33-47) 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.

b. Purging Run (Priming Operation)

(1) 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.

(2) 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 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 10.e.3.

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

c. Run-In Schedule (Pump Break-In)

(1) The nozzle discharge pressure shall be adjusted via the nozzle bypass valve and fuel pump discharge shutoff 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.

(2) Decrease input driveshaft speed and inlet air pressure to zero. Decrease fuel inlet pressure to zero psig.

(3) Close atomizer bypass valve.

OO-MAN-2015-00148

d. Acceleration Limiter Valve Setting

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

(2) 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 14, 10) and adjust the acceleration limiter adjusting screw (Figure 14, 20) to obtain the fuel nozzle pressure (crack pressure) specified.

Tighten nut (10). Recheck two times by cycling (energize/de-energize) fuel solenoid valve twice.

(3) If cracking pressure is unstable, loosen screws (Figure 14, 12), tap acceleration limiter cover (Figure 14, 14) gently until pressure stabilizes. Tighten screws (12) and recheck cracking pressure sensitivity. Reject the unit if it is unable to reliably meet data point requirements.

(4) Reconnect air line to acceleration limiter.

CAUTION

Do not operate the fuel control unit longer than 1 consecutive minute with the fuel solenoid valve

(Figure 19, 8) closed. Internal damage may result.

e. Relief Valve Setting

(1) Beginning with the fuel solenoid valve in the closed position, adjust the input parameters to the settings specified in data point 5.a. Then cycle (energize/de-energize) the fuel solenoid valve twice to check the relief valve.

(2) Add or remove washer (Figure 14, Sheet 2, 65) as required to obtain required pressure.

Repeat relieve valve check if washers (65) are added or removed.

(3) Reject the unit if it is unable to meet data point requirements.

f. Governor Set Point (Operational Conditions)

(1) Adjust the input parameters to the settings specified in data point 6.a. Adjust the governor adjustment screw, as necessary, to obtain the required fuel flow.

g. Reduced Speed Fuel Flow

(1) Adjust the input parameters to the settings specified in data point 7.a. The nozzle discharge pressure shall be adjusted via the nozzle bypass valve and fuel pump discharge shutoff valve. If the fuel flow is less than the required value for data point 7.a, reject the unit.

(2) Decrease input driveshaft speed and inlet air pressure to zero. Decrease fuel inlet pressure to zero psig.

(3) Close atomizer bypass valve.

h. 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.

(1) Adjust the input parameters to the settings specified in data point 8.a.

(2) Decrease speed to obtain fuel flow rates as specified in data points 8.b and 8.c; record data at each point.

(3) Increase speed to obtain fuel flow rates as specified in data point 8.d and record data.

(4) Calculate speed droop and hysteresis as instructed.

OO-MAN-2015-00148

(5) If delta rpm is not within limits, use spring (Figure 14, 52) with higher pound per inch rate to increase delta rpm or use lower pound per inch rate spring to decrease delta rpm. If spring is replaced, re-perform paragraph 8.5.f “Governor Set Point”.

i. Acceleration Limiter Valve Cracking Pressure – Recheck

(1) Beginning with the fuel solenoid valve in the closed position, set the fuel control unit to the operating parameters listed in data point 9.a. Recheck crack pressure two times by cycling (energize/de-energize) fuel solenoid valve twice. If necessary, reset crack pressure as required and repeat this step.

(2) Lockwire screws (Figure 14, 12) using lockwire (33-66). Repeat Step 8.5.i.(1) after acceleration limiter valve has been lockwired. Reject the unit if it is unable to meet the data point requirements for fuel flow.

j. 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.

(1) Sequentially operate the fuel control unit at the input parameters listed in data points 9.a through 10.g. Record all data. Check repeatability and nozzle pressure fluctuations as instructed. Reject the unit if it is unable to meet data point requirements.

k. Final Governor Set Point

(1) Set the fuel control unit to the operating parameters listed in data point 11.a. If necessary, readjust governor set point as required and repeat this step.

(2) Lockwire screws (Figure 14, 48) using lockwire (33-66). Step 8.5.k.(1) shall be performed after governor has been lockwired. Reject the unit if it is unable to meet the data point requirements.

l. Input Shaft Seal Leakage Check

(1) Set the fuel control unit to the operating parameters listed in data point 12.a. The leakage rate from the fuel control input drive shaft seal into the drain cavity shall not exceed one drop.

m. Fuel Filter Inspection

(1) Adjust all inputs to zero.

(2) Remove and inspect fuel filter.

(3) If evidence of foreign particles is found, install a new filter; otherwise, reinstall the original element.

8.6 Preservation

a. Adjust input drive shaft speed to zero.

b. Adjust inlet air and fuel inlet pressures to zero.

c. Shut off fuel, air and electrical power supplies.

d. Disconnect electrical connector from fuel solenoid valve.

e. Provide a suitable drain container.

f. Disconnect fuel lines from fuel control unit. Drain line into drain container.

OO-MAN-2015-00148

g. Disconnect air lines to fuel control unit.

h. Perform Preservation in accordance with paragraph 10.

8.7 Post Test

a. Lockwire filter cap (Figure 14, 76), plugs (70 and 74), screws (48), and screws (12) using lockwire (33-66).

b. Remove fuel control unit from test setup. Drain fluids into drain container.

Do not use tape to cover openings

c. Install protector cover over drive shaft (Figure 14, 87) and secure to unit.

d. Plug all openings and place fuel control unit in a dust and waterproof container.

TO 2G‐GTC85‐33‐9

WP 005 00 OO‐MAN‐2015‐00148

371688‐101 Results

2G‐GTCP85‐33‐9

T.O.

Paragraph Number

Required Actual Required Actual Required Actual Required Actual Required Actual Required Actual

8.5.a 1 a Close 5 ± 1 50 ± 1 PASS / FAIL a Close Close 1/2 ± 1/4 20 ± 5 0 0 b Close Close 20 ± 5 800 ± 50 0 a 10 ± 1 15 ± 1 500 ± 100 35 ± 1 25 ± 10 Record b 5 ± 1 15 ± 1 1500 ± 100 35 ± 1 65 ± 25 Record c 5 ± 1 15 ± 1 2500 ± 100 35 ± 1 165 ± 25 Record d 5 ± 1 15 ± 1 3500 ± 100 35 ± 1 275 ± 50 Record

8.5.d 4 a Open/ Close

Close 15 ± 1 900 ± 25

(open to atmosphere)

60 ± 1 0 PASS / FAIL

8.5.e 5 a Open/ Close

Close 15 ± 1 3500 ± 25 50 ± 1 475‐550 PASS / FAIL

8.5.f 6 a Open Close 10 ± 1 15 ± 1 4595 ± 2 35 ± 1 Record 107‐110 PASS / FAIL

8.5.g 7 a Open

Adjustable (Used to adjust nozzle discharge pressure)

15 ± 1 4345 ± 2 35 ± 1 300 ± 10 400 min PASS / FAIL a Open Close 15 ± 1 Record 35 ± 1 Record 85 ± 5 b Open Close 15 ± 1 Record 35 ± 1 Record 107‐110 c Open Close 15 ± 1 Record 35 ± 1 Record 217‐220 d Open Close 15 ± 1 Record 35 ± 1 Record 107‐110 e 45‐70 f 10 max

8.5.b

Operator:

Nozzle Discharge Pressure (Back Pressure)

(psig)

Pump Discharge Pressure (psig)

For each testing sequence circle the applicable result.

PASS / FAIL

PASS / FAIL

PASS / FAIL

Outputs

Fuel Flow Rate (pph)

Reduced Speed Fuel Flow

Part Number, Fuel Control Unit:

(Acceleration Limiter Valve, Air Inlet) (psig)

Time Required (minutes)

Solenoid Position (open/ close)

Nozzle/ Atomizer Bypass Valve (open/ close)Data Point

Run‐in Schedule (Pump break‐in)

Input Driveshaft Speed

(RPM)

Fuel Inlet Pressure (psig)

Table 5 ‐ Testing Operation(s) and Data Point(s) SN: Date:

8.5.c

Adjustable

(Used to adjust nozzle discharge pressure)

Open3

Test Sequence

Purging Run (Priming Operation)

Air Leakage Check, Acceleration Limiter Valve

InputsMachine Settings and Duration

Applicable T.O.(s):

Acceleration Limiter Valve Setting

Relief Valve Setting

Governor Set Point (Operational Conditions)

Speed Droop and Hysteresis

Record Speed Droop (7.b minus 7.c)

Record Hysteresis (7.d minus 7.b)

8.5.h

TO 2G‐GTC85‐33‐9

WP 005 00 OO‐MAN‐2015‐00148

371688‐101 Results

2G‐GTCP85‐33‐9

T.O.

Paragraph Number

Required Actual Required Actual Required Actual Required Actual Required Actual Required Actual

8.5.i 9 a Open/ Close

Close 15 ± 1 900 ± 25

(open to atmosphere)

60 ± 1 0 PASS / FAIL

Low Speed Initial Setting a Open Close 1/2 ± 1/4 15 ± 1 Record 35 ± 1 Record 220‐230

Speed Increase to Set‐ Point b Open Close 15 ± 1 Record 35 ± 1 Record 107‐110

Speed Decrease c Open Close 15 ± 1 4345 ± 5 35 ± 1 Record Record

Speed Increase, Return to Set‐Point d Open Close 15 ± 1 Record 35 ± 1 Record 107‐110

Ramp Down e Open Open 15 ± 1 0 0 0 0

Shutdown f Close Open 0 0 0 0 0

Repeatability Check g Open Close 15 ± 1 Record 35 ± 1 Record 107‐110

Maximum value within data points: 9.b, 9.d, and 9.g h 4605 max Record

Minimum value within data points: 9.b, 9.d, and 9.g i 4585 min Record

Maximum difference between data points:

9.h ‐ 9.i

J 15 max 14 max

8.5.k 11 a Open Close 10 ± 1 15 ± 1 4595 ± 2 35 ± 1 Record 107‐110 PASS / FAIL

8.5.l 12 a Close Close 3 +1/ ‐0 2 ± 1 4595 ± 5 35 ± 1 PASS / FAIL

Final Governor Set Point

Fuel Filter Inspection and Input Shaft Seal Leakage Check

Acceleration Limiter Valve Cracking Pressure ‐ Recheck

8.5.j

Repeatability and N ozzle Pressure Fluctuation

10 PASS / FAIL

(Acceleration Limiter Valve, Air Inlet) (psig)

Nozzle Discharge Pressure (Back Pressure)

(psig)

Pump Discharge Pressure (psig)

Fuel Flow Rate (pph)

For each testing sequence circle the applicable result.Test Sequence Data Point

Applicable T.O.(s):

Solenoid Position (open/ close)

Nozzle/ Atomizer Bypass Valve (open/ close)

Time Required (minutes)

Fuel Inlet Pressure (psig)

Input Driveshaft Speed

(RPM)

Table 5 (continued)‐ Testing Operation(s) and Data Point(s) SN: Date: Operator:

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