C-17FuelAccessories_TestInstruction.pdf.pdf

T.O. 2G-GTCP331-3-2

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6.1.8.6. Perform magnetic particle inspection in accordance with ASTM E1444.

6.2. Inspect identification plate (IPB Figure 11-1, Item 102) as follows:

6.2.1. Inspect mounting ears for wear or damage. Wear or damage that prevent retention of the plate with both screws is grounds for rejection.

6.2.2. Inspect part number and serial number markings for legibility. Replace if not legible.

6.3. Inspect inlet filter body (IPB Figure 11-3, View D, Item 90) as follows:

6.3.1. Visually inspect for cracks. No cracks permitted.

6.3.2. Visually inspect for dents in filter body. Dents in filter body shall not exceed 0.030 inches in depth.

6.3.3. Visually inspect machined surfaces such as bolt flange and packing groove for wear or damage. Damage less than 0.005 inch in depth is acceptable for continued service. Hand finish to remove burrs and raised metal.

No other damage permitted.

6.4. Inspect differential pressure indicator (IPB Figure 11-3, Detail F, Item 100) as follows:

6.4.1. Visually inspect for cracks. No cracks permitted.

6.4.2. Visually inspect electrical connector for damaged threads, keys, bent or broken pins. No damage permitted.

Visually inspect wrenching hex for wear or damage. Wear or damage shall not exceed 0.030 inch in depth.

6.4.3. Visually inspect machined surfaces such as threads, safety wire holes, and packing grooves for wear or damage. Damage less than 0.005 inch in depth is acceptable for continued service. Hand finish to remove burrs and raised metal. No other damage permitted.

6.4.4. If malfunction is suspected, test differential pressure indicator as follows:

6.4.4.1. General test instructions:

6.4.4.1.1. All readings and measurements are to be made using the automated test software in the 281600-

7-1 Fuel Accessory Test Stand unless otherwise specified.

6.4.4.1.2. Install differential pressure indicator with packings (IPB Figure 11-3, Detail F, Items 110 and

120) into TE3310513-1 Test Fixture.

6.4.4.1.3. Maintain a fuel inlet temperature of 80 + 15°F throughout the test procedure.

6.4.4.2. Perform external leakage test as follows:

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Construct test hook-up as shown in Figure

6-1.

Figure 6-1. Differential Pressure Indicator Hook-up #1

6.4.4.2.1. Adjust FUEL SUPPLY to 200 + 10 psig.

6.4.4.2.2. Maintain this pressure for 1 minute minimum.

6.4.4.2.3. Observe external surfaces of differential pressure indicator for signs of leakage. No leakage permitted. Record results on test data sheet. See Figure 6-3

6.4.4.2.4. Adjust supply pressure to zero.

6.4.4.3. Perform initial condition test as follows:

6.4.4.3.1. Connect TE3310618-1 test cable as follows:

6.4.4.3.1.1. Connect cable labeled UNIT to differential pressure indicator electrical connector.

6.4.4.3.1.2. Connect cable labeled PIN 1 to the positive terminal of a digital multimeter.

6.4.4.3.1.3. Connect cable labeled Pin 2 to the negative terminal of a digital multimeter.

6.4.4.3.1.4. Leave remaining cables disconnected at this time.

6.4.4.3.2. Construct test hook-up as shown in Figure 6-2.

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Figure 6-2. Differential Pressure Indicator Hook-up #2

6.4.4.3.1. With FUEL SUPPLY at 0 + 0.5 psig, observe digital multimeter. Digital multimeter shall indicate open circuit (resistance greater than 1K ohms between pins 1 and 2). Record result on test data sheet. See Figure 6-3.

6.4.4.4. Perform indicator test as follows. This step is not applicable for differential pressure indicator P/N

E3311028-1:

6.4.4.4.1. Slowly increase FUEL SUPPLY pressure until red band on differential pressure indicator extends. Red band shall extend when pressure is within 3.5 to 5 psig. Record pressure on test data sheet. See Figure 6-3.

6.4.4.5. Perform switch test as follows:

6.4.4.5.1. Continue to increase FUEL SUPPLY pressure until switch closes as indicated by digital multimeter (resistance less than 2 ohms between pins 1 and 2). Switch shall close when pressure is within 7.0 +/- 0.5 psig. Record pressure on test data sheet. See Figure 6-3.

6.4.4.6. Perform reset test as follows. This step is not applicable for differential pressure indicator P/N

E3311028-1:

6.4.4.6.1. Adjust FUEL SUPPLY to 0 + 0.5 psig.

6.4.4.6.2. Manually reset indicator by pushing red band into indicator housing. Reject unit if indicator does not reset.

6.4.4.6.3. Observe digital multimeter. Digital multimeter shall indicate an open circuit (resistance greater than 1K ohms between pins 1 and 2). Record results on test data sheet. See Figure 6-3.

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6.4.4.7. Remove differential pressure indicator from test hook-up.

C-17: P/N: PCN:

Differential Pressure Indicator

Inlet Pressure

(psig) Leakage Continuity

Pins 1 and 2 Result

Test Step Low Limit Actual

High Limit Limit Actual Requirement Actual

Pass or Fail

External Leakage Test 190 210 None

Initial Condition Test -0.5 0.5 Open

Indicator Test 3.5 5

Switch Test 6.5 7.5 Closed

Reset Test -0.5 0.5 Open

Final Result:

Figure 6-3. Test Data Sheet, Differential Pressure Indicator

6.5. Inspection of fuel solenoid valve (IPB Figure 11-3, Detail G, Item 130).

6.5.1. Visually inspect for cracks. No cracks permitted.

6.5.2. Visually inspect electrical connector for damaged threads, keys, bent or broken pins. No damage permitted.

6.5.3. Visually inspect machined surfaces such as bolt flange, bolt holes, and packing grooves for wear or damage.

Damage less than 0.005 inch in depth is acceptable for continued service. Hand finish to remove burrs and raised metal. No other damage permitted.

6.5.4. If malfunction is suspected, test solenoid valve as follows:

6.5.4.1. General test instructions:

6.5.4.1.1. All readings and measurements are to be made using the automated test software in the 281600-

7-1 Fuel Accessory Test Stand unless otherwise specified.

6.5.4.1.2. Install fuel solenoid valve with packings (IPB Figure 11-3, Detail G, Items 140, 150, and 160) into TE3310709-1 Test Fixture.

6.5.4.1.3. Maintain a fuel inlet temperature of 80 + 15°F throughout the test procedure.

6.5.4.2. Perform case ground resistance test as follows:

6.5.4.2.1. Connect TE3310712-1 Test Cable as follows:

6.5.4.2.1.1. Connect cable labeled SOL to fuel solenoid electrical connector.

6.5.4.2.1.2. Connect cable labeled CASE to fuel solenoid case.

6.5.4.2.1.3. Connect remaining cables in accordance with the following instructions.

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6.5.4.2.2. Measure the resistance between PIN 3 and CASE using a digital multimeter. Resistance shall not exceed 1 ohm. Record resistance on test data sheet (Figure 6-7).

6.5.4.3. Perform coil resistance test as follows:

6.5.4.3.1. Connect TE3310712-1 Test Cable as specified in step 6.5.4.2.1.

6.5.4.3.2. Measure the resistance between PIN 1 and PIN 2 using a digital multimeter. Resistance shall be within 20 to 30 ohms. Record resistance on test data sheet (Figure 6-7)

6.5.4.4. Perform insulation resistance test as follows:

WARNING

High voltage is present during insulation resistance test. Keeps away from unit under test while voltage is applied.

6.5.4.4.1. Connect TE3310712-1 Test Cable as specified in step 6.5.4.2.1.

6.5.4.4.2. Measure the resistance between PIN 1 and PIN 3 using a 500 VDC insulation resistance tester.

Insulation resistance shall be 40 megohms minimum. Record insulation resistance on test data sheet (Figure 6-7)

6.5.4.5. Perform outlet leakage test #1 as follows:

6.5.4.5.1. Construct test hookup as shown in Figure 6-4.

6.5.4.5.2. Connect TE3310712-2 Test Cable as follows:

6.5.4.5.2.1. Connect cable labeled SOL to fuel solenoid electrical connector.

6.5.4.5.2.2. Connect cable labeled E10B to console connector.

6.5.4.5.3. With fuel solenoid de-energized, adjust FUEL SUPPLY to 5 + 2 psig.

6.5.4.5.4. Energize fuel solenoid valve with 15 + 0.5 VDC, then de-energize fuel solenoid valve.

WARNING

Calibration fluid may flow from open outlet port, causing a hazardous condition. Direct open outlet port towards test stand sink.

6.5.4.5.5. Disconnect hose from OUTLET PORT.

6.5.4.5.6. Wait at least one minute for leakage to stabilize.

6.5.4.5.7. Observe leakage from OUTLET PORT for 3 minutes minimum. Leakage shall not exceed 5 drops in a 3 minute period. Record leakage on test data sheet (Figure 6-7).

6.5.4.5.8. Re-connect hose to OUTLET PORT.

6.5.4.5.9. Maintain this condition for the next test step.

6.5.4.6. Perform outlet leakage test #2 as follows:

6.5.4.6.1. With test condition as previously established, adjust FUEL SUPPLY to 100 + 5 psig.

6.5.4.6.2. Energize fuel solenoid valve with 15 + 0.5 VDC, then de-energize fuel solenoid valve.

Calibration fluid may flow from open outlet port, causing a hazardous condition. Direct open outlet port towards test stand sink.

6.5.4.6.3. Disconnect hose from OUTLET PORT.

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6.5.4.6.4. Wait at least one minute for leakage to stabilize

6.5.4.6.5. Observe leakage from OUTLET PORT for 3 minutes minimum. Leakage shall not exceed 5 drops in a 3 minute period. Record leakage on test data sheet (Figure 6-7).

6.5.4.6.6. Re-connect hose to OUTLET PORT.

6.5.4.6.7. Maintain test condition for the next test step.

Figure 6-4. Fuel Solenoid Hook-up # 1

6.5.4.7. Perform pull-in voltage test as follows:

6.5.4.7.1. With test condition as previously established, slowly increase voltage applied to fuel solenoid until valve opens.

6.5.4.7.2. Observe voltage when fuel solenoid valve opens. Voltage shall not exceed 10 VDC. Record voltage on test data sheet (Figure 6-7).

6.5.4.7.3. De-energize fuel solenoid valve.

6.5.4.7.4. Adjust FUEL SUPPLY pressure to zero.

6.5.4.8. Perform bypass leakage test #1 as follows:

6.5.4.8.1. Construct test hookup as shown in Figure 6-5.

6.5.4.8.2. Energize fuel solenoid valve with 15 + 0.5 VDC.

6.5.4.8.3. .

6.5.4.8.4. Adjust FUEL SUPPLY to 100 + 5 psig.

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Calibration fluid may flow from open bypass port, causing a hazardous condition.

Direct open bypass port towards test stand sink.

6.5.4.8.5. Disconnect hose from BYPASS PORT.

6.5.4.8.6. Wait at least one minute for leakage to stabilize.

6.5.4.8.7. Observe leakage from BYPASS PORT for 3 minutes minimum. Leakage shall not exceed 5 drops in a 3 minute period. Record leakage on test data sheet (Figure 6-7)

6.5.4.8.8. Reconnect hose to BYPASS PORT.

6.5.4.8.9. Maintain this test condition for the next test step.

6.5.4.9. Perform bypass leakage test #2 as follows:

6.5.4.9.1. With test condition as previously established, adjust FUEL SUPPLY to 1000 + 20 psig.

6.5.4.9.2. Adjust back pressure on OUTLET RETURN to obtain 630 + 50 lb/hr flow.

Calibration fluid may flow from open bypass port, causing a hazardous condition.

Direct open bypass port towards test stand sink.

6.5.4.9.3. Disconnect hose from BYPASS PORT.

6.5.4.9.4. Wait at least one minute for leakage to stabilize.

6.5.4.9.5. Observe leakage from BYPASS PORT for 3 minutes minimum. Leakage shall not exceed 5 drops in a 3 minute period. Record leakage on test data sheet (Figure 6-7).

6.5.4.9.6. Reconnect hose to BYPASS PORT.

6.5.4.9.7. Maintain this test condition for the next test step.

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Figure 6-5. Fuel Solenoid Hook-up #2

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6.5.4.10. Perform drop-out voltage test #1 as follows:

6.5.4.10.1. With test condition as previously established, slowly decrease voltage to fuel solenoid valve until it closes.

6.5.4.10.2. Observe voltage when fuel solenoid valve closes. Voltage shall not be less than 1 VDC. Record voltage on test data sheet (Figure 6-7).

6.5.4.10.3. Maintain this test condition for the next test step. Maintain position of back pressure valve on

OUTLET RETURN for the next test step.

6.5.4.11. Perform drop-out voltage test #2 as follows:

6.5.4.11.1. With test condition as previously established, energize fuel solenoid valve with 15 + 0.5 VDC.

6.5.4.11.2. Adjust FUEL SUPPLY to 100 + 5 psig.

6.5.4.11.3. Slowly decrease voltage to fuel solenoid valve until it closes.

6.5.4.11.4. Observe voltage when fuel solenoid valve closes. Voltage shall not be less than 1 VDC. Record voltage on test data sheet (Figure 6-7).

6.5.4.11.5. Maintain this test condition for the next test step.

6.5.4.12. Perform outlet pressure drop test as follows:

6.5.4.12.1. Fully open back pressure valve on OUTLET RETURN.

6.5.4.12.2. Energize fuel solenoid valve with 15 + 0.5 VDC.

6.5.4.12.3. Adjust FUEL SUPPLY as necessary to achieve 630 + 50 pounds per hour fuel flow.

6.5.4.12.4. Observe the difference between the FUEL SUPPLY PRESSURE and the OUTLET PRESSURE.

The difference shall not exceed 50 psid. Record the difference on test data sheet (Figure 6-7).

6.5.4.12.5. Adjust FUEL SUPPLY pressure to zero.

6.5.4.13. Perform bypass pressure drop test as follows:

6.5.4.13.1. De-energize fuel solenoid valve.

6.5.4.13.2. Adjust FUEL SUPPLY pressure as necessary to achieve 630 + 50 pounds per hour fuel flow.

6.5.4.13.3. Observe the difference between the FUEL SUPPLY PRESSURE and the BYPASS PRESSURE.

The difference shall not exceed 500 psid. Record the difference on test data sheet (Figure 6-7).

6.5.4.13.4. Adjust FUEL SUPPLY pressure to zero.

6.5.4.14. Perform reverse flow leakage test as follows:

6.5.4.14.1. Construct test hookup as shown in Figure 6-6.

6.5.4.14.2. Energize fuel solenoid with 15 + 0.5 VDC.

6.5.4.14.3. Adjust FUEL SUPPLY to 40 + 4 psig.

6.5.4.14.4. Wait at least 1 minute minimum for leakage to stabilize.

6.5.4.14.5. Observe leakage from outlet port. Leakage must not exceed 10 cc/minute. Record leakage on test data sheet (Figure 6-7).

6.5.4.15. Remove solenoid valve from test hook-up.

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Figure 6-6. Fuel Solenoid Hook-up #3

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Figure 6-7. Test Data Sheet, Solenoid Valve

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6.6. Inspection of torque motor (IPB Figure 11-3, Detail H, Item 180).

6.6.1. Visually inspect for cracks. No cracks permitted.

6.6.2. Visually inspect electrical connector for damaged threads, keys, bent or broken pins. No damage permitted.

6.6.3. Visually inspect inlet tube for wear, damage, burrs or sharp edges. No damage permitted.

6.6.4. Visually inspect machined surfaces such as bolt flange, bolt holes, and packing grooves for wear or damage.

Damage less than 0.005 inch in depth is acceptable for continued service. Hand finish to remove burrs and raised metal. No other damage permitted.

6.6.5. If malfunction is suspected, test torque motor as follows:

6.6.5.1. General test instructions:

6.6.5.1.1. All readings and measurements are to be made using the automated test software in the 281600-

7-1 Fuel Accessory Test Stand unless otherwise specified.

6.6.5.1.2. Install torque motor with packings (IPB Figure 11-3, Detail H and Detail J, Items 190 and 210) into TE3310516-1 Test Fixture.

6.6.5.1.3. Maintain a fuel inlet temperature of 80 + 15°F throughout the test procedure.

6.6.5.1.4. Maintain an inlet pressure within 225 + 25 psig throughout the test procedure.

6.6.5.1.5. Maintain DIFFERENTIAL PRESSURE at 50.0 + 0.3 psid throughout this test procedure. Adjust back pressure on OUTLET RETURN at each test step to maintain differential pressure within this range.

6.6.5.1.6. Changes in torque motor current shall be made only in the increasing or decreasing direction as specified. If the desired current is over-shot, return to the previous test condition and try again.

6.6.5.2. Perform case ground resistance test as follows:

6.6.5.2.1. Connect TE3310617-1 Test Cable as follows:

6.6.5.2.1.1. Connect cable labeled UNIT to torque motor electrical connector.

6.6.5.2.1.2. Connect cable labeled CASE to torque motor connector case.

6.6.5.2.1.3. Connect remaining cables in accordance with the following instructions.

6.6.5.2.2. Measure the resistance between pin 3 and CASE using a digital multimeter. Resistance shall not exceed 1 ohms. Record resistance on test data sheet (Figure 6-9)

6.6.5.3. Perform coil resistance test as follows:

6.6.5.3.1. Connect TE3310617-1 Test Cable as specified in Step 6.6.5.2.1.

6.6.5.3.2. Measure the resistance between pin 1 and pin 2 using a digital multimeter. Resistance shall be within 20 to 40 ohms. Record resistance on test data sheet (Figure 6-9)

6.6.5.4. Perform insulation resistance test as follows:

6.6.5.4.1. Connect TE3310617-1 Test Cable as specified in Step 6.6.5.2.1.

6.6.5.4.2. Measure the resistance between pin 1 (positive) and pin 3 (negative) using a 500 VDC insulation resistance tester. Insulation resistance shall be 40 megohms minimum. Record insulation resistance on test data sheet (Figure 6-9)

6.6.5.5. Perform hysteresis test as follows:

6.6.5.5.1. Construct test hookup as shown in Figure 6-8.

6.6.5.5.1.1. Connect TE3310519-1 Test Cable as follows:

6.6.5.5.1.1.1. Connect cable labeled TM to fuel control unit torque motor connector.

6.6.5.5.1.1.2. Do not connect cable labeled SOL at this time.

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6.6.5.5.1.1.3. Connect cable labeled E10B to test stand E10B connector.

6.6.5.5.1.1.4. Do not connect cable labeled E10A at this time.

Figure 6-8. Torque Motor Hook-up #1

6.6.5.5.2. Perform a current cycle as follows:

6.6.5.5.2.1. Energize torque motor with approximately 150 milliamps.

6.6.5.5.2.2. Cycle the torque motor current from 150 milliamps to 0 milliamps and back to 150 milliamps within one half second or less. Repeat this cycle at least two more times.

6.6.5.5.2.3. Adjust torque motor current to zero milliamps.

6.6.5.5.3. Adjust FUEL SUPPLY to 225 + 25 psig

6.6.5.5.4. Increase torque motor current to 17.0 + 0.1 milliamps

6.6.5.5.5. Record fuel flow value on test data sheet (see Figure 6-9).

6.6.5.5.6. Increase torque motor current to 25.0 + 0.1 milliamps.

6.6.5.5.7. Record fuel flow value on test data sheet (see Figure 6-9).

6.6.5.5.8. Increase torque motor current to 55.0 + 0.1 milliamps.

6.6.5.5.9. Record fuel flow value on test data sheet (see Figure 6-9).

6.6.5.5.10. Increase torque motor current to 100.0 + 0.1 milliamps.

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6.6.5.5.11. Record fuel flow value on test data sheet (see Figure 6-9).

6.6.5.5.12. Increase torque motor current to 250.0 + 5.0 milliamps.

6.6.5.5.13. Decrease torque motor current to 100.0 + 0.1 milliamps.

6.6.5.5.14. Fuel flow shall be within 6 pounds per hour of the value recorded in Step 6.6.5.5.11. Record fuel flow value on test data sheet (see Figure 6-9).

6.6.5.5.15. Decrease torque motor current to 55.0 + 0.1 milliamps.

6.6.5.5.16. Fuel flow shall be within 5 pounds per hour of the value recorded in Step 6.6.5.5.9. Record fuel flow value on test data sheet (see Figure 6-9).

6.6.5.5.17. Decrease torque motor current to 25.0 + 0.1 milliamps.

6.6.5.5.18. Fuel flow shall be within 5 pounds per hour of the value recorded in Step 6.6.5.5.7. Record fuel flow value on test data sheet (see Figure 6-9).

6.6.5.5.19. Decrease torque motor current to 17.0 + 0.1 milliamps.

6.6.5.5.20. Fuel flow shall be within 5 pounds per hour of the value recorded in Step 6.6.5.5.5. Record fuel flow value on test data sheet (see Figure 6-9).

6.6.5.5.21. Maintain this test condition for the next test step.

6.6.5.6. Perform increasing flow test as follows:

6.6.5.6.1. With test condition as previously established, decrease torque motor current to 0.0 + 0.1 milliamps.

6.6.5.6.2. Verify FUEL SUPPLY is set to 225 + 25 psig.

6.6.5.6.3. Fuel flow shall be within 10 to 36 pounds per hour. Record fuel flow value on test data sheet

(see Figure 6-9).

6.6.5.6.4. Increase torque motor current to 10.0 + 0.1 milliamps.

6.6.5.6.5. Fuel flow shall be within 10 to 45 pounds per hour. Record fuel flow value on test data sheet

(see Figure 6-9).

6.6.5.6.6. Increase torque motor current to 12.0 + 0.1 milliamps.

6.6.5.6.7. Fuel flow shall be within 30 to 46 pounds per hour. Record fuel flow value on test data sheet

(see Figure 6-9).

6.6.5.6.8. Increase torque motor current to 17.0 + 0.1 milliamps.

6.6.5.6.9. Fuel flow shall be within 41 to 51 pounds per hour. Record fuel flow value on test data sheet

(see Figure 6-9).

6.6.5.6.10. Increase torque motor current to 25.0 + 0.1 milliamps.

6.6.5.6.11. Fuel flow shall be within 58 to 72 pounds per hour. Record fuel flow value on test data sheet

(see Figure 6-9).

6.6.5.6.12. Increase torque motor current to 55.0 + 0.1 milliamps.

6.6.5.6.13. Fuel flow shall be within 124 to 154 pounds per hour. Record fuel flow value on test data sheet

(see Figure 6-9).

6.6.5.6.14. Increase torque motor current to 99.0 + 0.1 milliamps.

6.6.5.6.15. Fuel flow shall be at least 178 pounds per hour greater than the value observed in Step

6.6.5.6.11. Record fuel flow value on test data sheet (see Figure 6-9).

6.6.5.6.16. Increase torque motor current to 100.0 + 0.1 milliamps.

6.6.5.6.17. Fuel flow shall be within 237 to 267 pounds per hour. Record fuel flow value on test data sheet

(see Figure 6-9).

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6.6.5.6.18. Increase torque motor current to 200.0 + 0.1 milliamps.

6.6.5.6.19. Fuel flow shall be within 445 to 529 pounds per hour. Record fuel flow value on test data sheet

(see Figure 6-9).

6.6.5.6.20. Increase torque motor current to 250.0 + 0.1 milliamps.

6.6.5.6.21. Fuel flow shall be within 550 to 660 pounds per hour. Record fuel flow value on test data sheet

(see Figure 6-9).

6.6.5.6.22. Maintain this test condition for the next test step.

6.6.5.7. Perform decreasing flow test as follows:

6.6.5.7.1. With test condition as previously established, increase torque motor current to 260.0 + 5.0 milliamps.

6.6.5.7.2. Decrease torque motor current to 250.0 + 0.1 milliamps.

6.6.5.7.3. Fuel flow shall be within 550 to 660 pounds per hour. Record fuel flow value on test data sheet

(see Figure 6-9).

6.6.5.7.4. Decrease torque motor current to 200.0 + 0.1 milliamps.

6.6.5.7.5. Fuel flow shall be within 445 to 529 pounds per hour. Record fuel flow value on test data sheet

(see Figure 6-9).

6.6.5.7.6. Decrease torque motor current to 100.0 + 0.1 milliamps.

6.6.5.7.7. Fuel flow shall be within 237 to 267 pounds per hour. Record fuel flow value on test data sheet

(see Figure 6-9).

6.6.5.7.8. Decrease torque motor current to 99.0 + 0.1 milliamps.

6.6.5.7.9. Fuel flow shall be at least 178 pounds per hour greater than the value observed in Step

6.6.5.6.11. Record fuel flow value on test data sheet (seeFigure 6-9).

6.6.5.7.10. Decrease torque motor current to 55.0 + 0.1 milliamps.

6.6.5.7.11. Fuel flow shall be within 124 to 154 pounds per hour. Record fuel flow value on test data sheet

(see Figure 6-9).

6.6.5.7.12. Decrease torque motor current to 25.0 + 0.1 milliamps.

6.6.5.7.13. Fuel flow shall be within 58 to 72 pounds per hour. Record fuel flow value on test data sheet

(see Figure 6-9).

6.6.5.7.14. Decrease torque motor current to 17.0 + 0.1 milliamps.

6.6.5.7.15. Fuel flow shall be within 41 to 51 pounds per hour. Record fuel flow value on test data sheet

(see Figure 6-9).

6.6.5.7.16. Decrease torque motor current to 12.0 + 0.1 milliamps.

6.6.5.7.17. Fuel flow shall be within 30 to 46 pounds per hour. Record fuel flow value on test data sheet

(see Figure 6-9).

6.6.5.7.18. Decrease torque motor current to 10.0 + 0.1 milliamps.

6.6.5.7.19. Fuel flow shall be within 10 to 45 pounds per hour. Record fuel flow value on test data sheet

(see Figure 6-9).

6.6.5.7.20. Decrease torque motor current to 0.0 + 0.1 milliamps.

6.6.5.7.21. Fuel flow shall be within 10 to 36 pounds per hour. Record fuel flow value on test data sheet

(see Figure 6-9).

6.6.5.7.22. Adjust FUEL SUPPLY to zero.

6.6.5.8. Remove torque motor from test hook-up.

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Figure 6-9. Test Data Sheet, Torque Motor

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6.7. Inspect adapter (IPB Figure 11-3, Detail J, item 220) as follows:

6.7.1. Visually inspect for cracks. No cracks permitted.

6.7.2. Visually inspect for nicks, burrs, wear, or other damage. Damage less than 0.005 inch in depth is acceptable for continued service. Hand finish to remove raised metal. No other damage permitted.

6.8. Inspect spring seat (IPB Figure 11-3, Detail K, Item 230) as follows:

6.8.1. Visually inspect for nicks, burrs, or distortion. Replace if damaged.

6.9. Inspect spring (IPB Figure 11-3, Detail K, Item 240) as follows:

6.9.1. Visually inspect for wear or other damage. No damage permitted.

6.9.2. Inspect spring tension using equipment specified in Table 6-1. Spring length shall be 0.96 inch with load of

17.22 ± 0.86 pounds. Spring length shall be 0.86 inch with a load of 28.12 ± 1.4 pounds. Replace if requirements not met.

6.10. Inspect spring guide (IPB Figure 11-3, Detail K, Item 250) as follows:

6.10.1. Visually inspect for nicks, burrs, or distortion. Replace if damaged.

6.11. Inspect piston and sleeve (IPB Figure 11-3, Detail K, items 262 and 264) as follows:

6.11.1. Visually inspect for cracks. No cracks permitted.

NOTE

The differential pressure valve sleeve contains a deflector swaged into the internal passage.

Presence of the deflector does not constitute blockage. The swaged area in the deflector does not constitute damage. Sleeve shall not be rejected for these conditions.

6.11.2. Visually inspect fluid passages for blockage. No blockage permitted.

6.11.3. Visually inspect for nicks, burrs, and other damage. Hand finish to remove raised metal. No other damage permitted.

6.11.4. Inspect for freedom of movement by placing piston into sleeve. With sleeve horizontal, place one hand under sleeve and gradually tilt sleeve until piston slips out. Piston shall slip out before sleeve is rotated to a 45 degree angle. Repeat several times. Reject piston and sleeve if binding is observed.

6.12. Inspect retainer (IPB Figure 11-3, Detail K, Item 290) as follows:

6.12.1. Visually inspect for cracks. No cracks permitted.

6.12.2. Visually inspect wrenching hex for wear or damage. Wear or damage shall not exceed 0.030 inch in depth.

6.12.3. Visually inspect machined surfaces such as threads, safety wire holes, and packing grooves for wear or damage. Damage less than 0.005 inch in depth is acceptable for continued service. Hand finish to remove burrs and raised metal. No other damage permitted.

6.13. Inspect pressure relief valve (IPB Figure 11-3, Detail L, item 310) as follows:

6.13.1. Visually inspect for cracks. No cracks permitted.

6.13.2. Visually inspect fluid passages for blockage. No blockage permitted.

6.13.3. Visually inspect wrenching hex for wear or damage. Wear or damage shall not exceed 0.030 inch in depth.

6.13.4. Visually inspect remaining features such as threads, lockwire holes, and packing grooves for nicks, burrs, and sharp edges. Hand finish to remove raised metal. No other damage permitted.

6.13.5. If disassembled, inspect components as follows:

6.13.5.1. Visually inspect poppet (IPB Figure 11-3, Detail S, Item 330) for nicks, burrs, or distortion. Replace if damaged.

6.13.5.2. Visually inspect retainer (IPB Figure 11-3, Detail S, Item 340) for nicks, burrs, wear, or other damage.

Replace if damaged.

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6.13.5.3. Visually inspect spring (IPB Figure 11-3, Detail S, Item 350) for nicks, burrs, wear, or distortion.

Replace if damaged.

6.13.5.4. Visually inspect gland (IPB Figure 11-3, Detail S, Item 360) for nicks, burrs, wear, or damage. No damage permitted.

6.13.5.5. Visually inspect jamnut (IPB Figure 11-3, Detail S, Item 370) for nicks, burrs, wear, or damage.

Damage to wrenching hex less than 0.020 inch in depth is acceptable for continued service. No other damage permitted.

6.13.6. If malfunction is suspected, test pressure relief valve as follows:

6.13.6.1. General test instructions:

6.13.6.1.1. All readings and measurements are to be made using the automated test software in the 281600-

7-1 Fuel Accessory Test Stand unless otherwise specified.

6.13.6.1.2. Install pressure relief valve with packings (IPB Figure 11-3, Detail L, items 380 and 390) into

TE3310512-1 Test Fixture.

6.13.6.1.3. Maintain a fuel inlet temperature of 80 + 15°F throughout the test procedure.

6.13.6.2. Perform external leakage test as follows:

6.13.6.2.1. Construct test hook-up as shown in Figure 6-10.

6.13.6.2.1.1. Close OUTLET RETURN.

Figure 6-10. Pressure Relief Valve Hook-up #1

6.13.6.2.2. Adjust FUEL SUPPLY to 1000 + 10 psig.

6.13.6.2.3. Maintain this condition for 1 minute minimum.

6.13.6.2.4. Observe external surfaces of pressure relief valve for signs of leakage. No leakage permitted.

Record results on test data sheet (see Figure 6-11).

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6.13.6.3. Perform internal leakage test as follows:

6.13.6.3.1. Open OUTLET RETURN.

6.13.6.3.2. Adjust FUEL SUPPLY to 850 + 10 psig.

6.13.6.3.3. Disconnect hose from outlet port.

6.13.6.3.4. Observe outlet port for leakage. Leakage shall not exceed 10 cc/min. Record leakage on test data sheet (see Figure 6-11).

6.13.6.3.5. Reconnect hose to outlet port.

6.13.6.4. Perform crack pressure test as follows:

6.13.6.4.1. Slowly increase FUEL SUPPLY until pressure relief valve cracks open as indicated by a sudden increase in flow.

6.13.6.4.2. Observe FUEL SUPPLY pressure when pressure relief valve cracks open. Pressure shall be 900 psig minimum. Record pressure on test data sheet (see Figure 6-11).

6.13.6.5. Perform flow test as follows:

6.13.6.5.1. Slowly increase FUEL SUPPLY pressure as necessary to achieve a flow rate of 500 lb/hr minimum. FUEL SUPPLY pressure shall not exceed 1000 psig.

6.13.6.5.2. Record pressure on test data sheet (see Figure 6-11).

6.13.6.6. Perform reseat test as follows:

6.13.6.6.1. Decrease FUEL SUPPLY to 850 + 10 psig.

6.13.6.6.2. Disconnect hose from outlet port.

6.13.6.6.3. Observe outlet port for leakage. Leakage shall not exceed 10 cc/min. Record leakage on test data sheet (see Figure 6-11).

6.13.6.7. Remove pressure relief valve from test hook-up.

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Figure 6-11. Test Data Sheet, Pressure Relief Valve

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6.14. Inspect piston and sleeve (IPB Figure 11-3, Detail M, items 402 and 404) as follows:

6.14.1. Visually inspect for cracks. No cracks permitted.

6.14.2. Visually inspect fluid passages for blockage. No blockage permitted.

6.14.3. Visually inspect for nicks, burrs, and other damage. Hand finish to remove raised metal. No other damage permitted.

6.14.4. Inspect for freedom of movement by placing piston into sleeve. With sleeve horizontal, place one hand under sleeve and gradually tilt sleeve until piston slips out. Piston shall slip out before sleeve is rotated to a 45 degree angle. Repeat several times. Reject piston and sleeve if binding is observed.

6.15. Inspect spring (IPB Figure 11-3, Detail M, Item 420) as follows:

6.15.1. Visually inspect for wear or other damage. No damage permitted.

6.15.2. Inspect spring tension using equipment specified in Table 6-1. Spring length shall be 0.71 inch with load of

9.8 ± 0.5 pounds. Spring length shall be 0.90 inch with a load of 6.0 ± 1.1 pounds. Replace if requirements not met.

6.16. Inspect spring washer (IPB Figure 11-3, Detail M, Item 430) as follows:

6.16.1. Visually inspect for cracks. No cracks permitted.

6.16.2. Visually inspect for wear, damage, or distortion. None permitted.

6.16.3. Inspect spring washer tension using equipment specified in Table 6-1. Spring washer height shall be 0.060 to

0.080 inches with no load applied. Height shall be 0.030 to 0.050 inches with a load of 10.0 ± 1.0 pounds.

6.17. Inspect shims (IPB Figure 11-3, Detail M, Item 440) as follows:

6.17.1. Visually inspect for cracks, wear, burrs, or distortion. No damage permitted.

6.18. Inspect plug (IPB Figure 11-3, Detail M, Item 450) as follows:

6.18.1. Visually inspect for cracks. No cracks permitted.

6.18.2. Visually inspect wrenching hex for wear or damage. Wear or damage shall not exceed 0.020 inch in depth.

6.18.3. Visually inspect machined surfaces such as threads, lockwire holes, and packing grooves for wear or damage.

Damage less than 0.005 inch in depth is acceptable for continued service. Hand finish to remove burrs and raised metal. No other damage permitted.

6.19. Inspect strainer element (IPB Figure 11-3, Detail N, item 470) as follows:

6.19.1. Ultrasonic clean strainer element. If strainer element passes visual inspection, reuse is authorized.

6.19.2. Visually inspect screen area for cracks, deformities, tears, and clogged openings. Replace if damaged.

6.19.3. Visually inspect machined features such as packing grooves for wear or damage. Damage less than 0.005 inch in depth is acceptable for continued service. Hand finish to remove raised metal. No other damage permitted.

6.20. Inspect strainer element (IPB Figure 11-3, Detail T, item 470A) as follows:

6.20.1. Ultrasonic clean strainer element. If strainer element passes visual inspection, reuse is authorized.

6.20.2. Visually inspect screen area for cracks, deformities, tears, and clogged openings. Dents in screen less than 1/8 inch in depth are acceptable for continued service. No other damage permitted.

6.20.3. Visually inspect hex wrenching flats for wear or damage. Damage less than 0.030 inch in depth is acceptable for continued service. Hand finish to remove raised metal.

6.20.4. Visually inspect machined features such as threads and packing grooves for wear or damage. Damage less than 0.005 inch in depth is acceptable for continued service. Hand finish to remove raised metal. No other damage permitted.

6.21. Inspect plug (IPB Figure 11-3, Detail N, item 480) as follows:

6.21.1. If hex plug passes visual inspection, reuse is authorized.

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6.21.2. Visually inspect hex wrenching flats for wear or damage. Damage less than 0.030 inch in depth is acceptable for continued service. Hand finish to remove raised metal.

6.21.3. Visually inspect machined features such as threads and packing grooves for wear or damage. Damage less than 0.005 inch in depth is acceptable for continued service. Hand finish to remove raised metal. No other damage permitted.

6.22. Inspect shims (IPB Figure 11-3, Detail P, Item 510) as follows:

6.22.1. If shims pass visual inspection, reuse is authorized.

6.22.2. Visually inspect for cracks, wear, burrs, or distortion. No damage permitted.

6.23. Inspect spring (IPB Figure 11-3, Detail P, Item 520) as follows:

6.23.1. If spring passes visual inspection, reuse is authorized.

6.23.2. Visually inspect for wear or other damage. No damage permitted.

6.23.3. Inspect spring tension using equipment specified in Table 6-1. Spring length shall be 0.72 inch with a load of

13.6 ± 0.63 pounds. Spring length shall be 0.85 inch with a load of 6.8 ± 0.63 pounds. Replace if requirements are not met.

6.24. Inspect piston and sleeve (IPB Figure 11-3, Detail P, items 532 and 534) as follows:

6.24.1. Visually inspect for cracks. No cracks permitted.

6.24.2. Visually inspect fluid passages for blockage. No blockage permitted.

6.24.3. Visually inspect for nicks, burrs, and other damage. Hand finish to remove raised metal. No other damage permitted.

6.24.4. Inspect for freedom of movement by placing piston into sleeve. With sleeve horizontal, place one hand under sleeve and gradually tilt sleeve until piston slips out. Piston shall slip out before sleeve is rotated to a 45 degree angle. Repeat several times. Reject piston and sleeve if binding is observed.

6.25. Inspect hex plug (IPB Figure 11-3, Detail P, Item 550) as follows:

6.25.1. If hex plug passes visual inspection, reuse is authorized.

6.25.2. Visually inspect for cracks. No cracks permitted.

6.25.3. Visually inspect wrenching hex for wear or damage. Wear or damage shall not exceed 0.030 inch in depth.

6.25.4. Visually inspect machined surfaces such as threads, lockwire holes, and packing grooves for wear or damage.

Damage less than 0.005 inch in depth is acceptable for continued service. Hand finish to remove burrs and raised metal. No other damage permitted.

6.26. Inspect fuel filter bypass valve (IPB Figure 11-3, Detail R, Item 590) as follows:

6.26.1. Visually inspect for cracks. No cracks permitted.

6.26.2. Visually inspect fluid passages for blockage. No blockage permitted.

6.26.3. Visually inspect wrenching hex for wear or damage. Wear or damage shall not exceed 0.030 inch in depth.

6.26.4. Visually inspect remaining features such as threads, lockwire holes, and packing grooves for nicks, burrs, and sharp edges. Hand finish to remove raised metal. No other damage permitted.

6.26.5. If malfunction is suspected, test bypass valve as follows:

6.26.5.1. General test instructions:

6.26.5.1.1. All readings and measurements are to be made using the automated test software in the 281600-

7-1 Fuel Accessory Test Stand unless otherwise specified.

6.26.5.1.2. Install bypass valve with packings (IPB Figure 11-3, Detail R, items 600 and 610) into

TE3310511-1 Test Fixture.

6.26.5.1.3. Maintain a fuel inlet temperature of 80 + 15°F throughout the test procedure.

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6.26.5.2. Perform external leakage test as follows:

6.26.5.2.1. Construct test hook-up as shown in Figure 6-12.

Figure 6-12. Bypass Valve Hook-up #1

6.26.5.2.2. Adjust FUEL SUPPLY to 200 + 10 psig.

6.26.5.2.3. Maintain this condition for 1 minute minimum.

6.26.5.2.4. Observe external surfaces of bypass valve for signs of leakage. No leakage permitted. Record results on test data sheet (see Figure 6-16).

6.26.5.3. Perform internal leakage test as follows:

6.26.5.3.1. Construct test hook-up as shown in Figure 6-13.

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Figure 6-13. Bypass Valve Hook-up #2

Calibration fluid may flow from open outlet port, causing a hazardous condition. Direct open outlet port towards test stand sink.

6.26.5.3.2. Adjust FUEL SUPPLY to within 5 to 6 psig.

6.26.5.3.3. Observe outlet port for leakage. Leakage shall not exceed 1 drop per minute. Record results on test data sheet (see Figure 6-16).

6.26.5.4. Perform crack pressure test as follows:

6.26.5.4.1. Increase FUEL SUPPLY until valve cracks open as indicated by a sudden increase in flow from outlet port (approximately 10 cc/min).

6.26.5.4.2. When valve cracks open, FUEL SUPPLY shall be 7.5 + 1.0 psig. Record results on test data sheet (see Figure 6-16).

6.26.5.5. Perform flow test #1 as follows:

6.26.5.5.1. Construct test hook-up as shown in Figure 6-14.

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Figure 6-14. Bypass Valve Hook-up #3

6.26.5.5.2. Adjust FUEL SUPPLY as necessary to achieve 1000 + 100 lb/hr flow.

6.26.5.5.3. DIFFERENTIAL PRESSURE shall not exceed 13 psid. Record results on test data sheet (see

Figure 6-16).

6.26.5.6. Perform flow test #2 as follows:

6.26.5.6.1. Construct test hook-up as shown in Figure 6-15.

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Figure 6-15. Bypass Valve Hook-up #4

6.26.5.6.2. Adjust FUEL SUPPLY to 50 + 10 psig.

6.26.5.6.3. Adjust back pressure on OUTLET RETURN as necessary to achieve 900 - 1100 lb/hr flow.

6.26.5.6.4. DIFFERENTIAL PRESSURE shall not exceed 13 psid. Record results on test data sheet (see

Figure 6-16).

6.26.5.7. Perform reseat test as follows:

6.26.5.7.1. Construct test hook-up as shown in Figure 6-13.

Calibration fluid may flow from open outlet port, causing a hazardous condition. Use caution while adjusting supply pressure.

6.26.5.7.2. Adjust FUEL SUPPLY to 7.5 + 0.5 psig.

6.26.5.7.3. Observe outlet port for leakage. Leakage shall not exceed 10 cc/min. Record results on test data sheet (see Figure 6-16).

6.26.5.8. Perform final leakage test as follows:

6.26.5.8.1. Adjust FUEL SUPPLY to within 5 to 6 psig.

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6.26.5.8.2. Observe outlet port for leakage. Leakage shall not exceed 1 drop per minute. Record results on test data sheet (see Figure 6-16).

6.26.5.9. Remove bypass valve from test hook-up.

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Figure 6-16. Test Data Sheet, Bypass Valve