F-15FuelControl_TestInstruction.pdf.pdf

T.O. 2JA3-50-3

SWP 014 02

SUBORDINATE WORK PACKAGE

LIST OF EFFECTIVE SWP PAGES

Total number of pages in this SWP is 36, consisting of the following:

Page Change Page Change Page Change

No. No. No. No. No. No.

1 - 4 . . . . . . . . . . . . . . . . . . . . . 25 24 Blank . . . . . . . . . . . . . . . . . . 3 25 - 36 Deleted 5 - 23

TABLE OF CONTENTS

Paragraph Page Paragraph Page

Reference Material Required . . . . . . . . . . . 2 3.4 Pump Break-in and Capacity Check Applicable TCTOs . . . . . . . . . . . . . . . . . . 2 3.5 Installation of Fuel Control onto Test Consumable Materials . . . . . . . . . . . . . . . . 2 Stand and Preparation for Testing Applicable Support Equipment . . . . . . . . . 2 4 Acceptance Tests

1 Foreword . . . . . . . . . . . . . . . . . . . . . . . . . 5 4.1 Fuel Control Adjustment and 2 Safety Summary . . . . . . . . . . . . . . . . . . . . 5 Acceptance Test

2.1 Warning and Caution Statements . . . . . . . . 5 4.2 Pump Capacity Test

2.2 Hazardous Materials Warnings . . . . . . . . . 5 5 Troubleshooting 3 Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 6 Post Test Procedures

3.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . 5 6.1 Preservation and Removal from Test

3.2 JFS Fuel Control Test Stand Stand

Requirements . . . . . . . . . . . . . . . . . . . . . 5 6.2 Final Assembly and Preparation for

3.3 Operation of Test Stand . . . . . . . . . . . . . . 6 Shipment

TECHNICAL PROCEDURES

FUEL CONTROL ASSEMBLY TESTING

EFFECTIVITY: PART NO. 367100-1/-2/-3

LIST OF ILLUSTRATIONS

Figure Title Page Figure Title Page

1 Support Equipment ............................................ 3 7 Acceleration Schedule Chart 2 Simulator Differential Pressure Limits . . . 8 8 Deleted 3 Fuel Control Connections and Ports .................. 9 9 Deleted 4 Fuel Control Test Setup Schematic ................. 10 10 Deleted 5 Fuel Control Fuel System Schematic .............. 15 11 Deleted 6 Measurement of Fuel Control 12 Deleted

Acceleration Timer Shaft Tang Engagement

LIST OF TABLES

Number Title Page Number Title Page

Sheet

REFERENCE MATERIAL REQUIRED

NONE

APPLICABLE TCTOs

NONE

CONSUMABLE MATERIALS

Nomenclature Specification/Part No. CAGE Code

Lubricant Sealing Compound Sn10 Solder Lubricating Oil Calibration Fluid

Petrolatum, Technical VV-P-246A MIL-S-23586, Type I

QQ-S-471

MIL-PRF-6081D GR1010

MIL-PRF7024 Type II

APPLICABLE SUPPORT EQUIPMENT

Part Number Nomenclature Figure Number

AM/PSM-37

MS27534-20

STK-2615-19

281600-4-1

Multimeter Wire Installer and Extractor Puller Test Stand, Fuel Accessories

Figure 1, 1 291496-1 Adapter, Speed Increaser Figure 1, 2 291497-1 Controller, Solenoid Figure 1, 3 291498-1 Simulator, Fuel Manifold Figure 1, 4 291704-1 Mechanical Bearing Puller Figure 1, 5 291705-1 Valve Seat Puller Figure 1, 6 291707-1 Torque Wrench Adapter Figure 1, 7 291708-1 Wrench Adapter Figure 1, 8 291709-1 Mechanical Sleeve Puller Figure 1, 9 291710-1 Wrench, Screw Adjusting Figure 1, 10 291712-1 Seal Installing Tool Figure 1, 11 291715-1 Sleeve Adjusting Wrench Figure 1, 12 291824-1 102187-53-6

Adapter Adapter (Alternate to P/N 291824-1)

Figure 1, 13 Figure 1, 13

293031-1 Governor Cage Puller Kit 293597-1 Pin Lapping Holder Figure 1, 14 293598-1 Force Gage Adapter Figure 1, 15 293599-1 Connector Potting Fixture Figure 1, 16 8319798 Removal Tool 8319812 T-handle Figure 1, 17

1 Break-In and Capacity Conditions ....................... 7 3 Troubleshooting 2 Fuel Control Acceptance Test Data

8319813 Puller Figure 1, 18 8750578 Puller 9448978

SPLSF15140001

296070-1 296783-1 102187-53-1

SPLSF15140001

296070-1 296783-1

Puller Dimension Tool Fuel Control Test Adapter Fuel Pump Test Adapter Fuel Control Drive Shaft Dimension Tool Fuel Control Test Adapter Fuel Pump Test Adapter

Figure 1. Support Equipment (Sheet 1 of 2)

Figure 1. Support Equipment (Sheet 2)

1. FOREWORD.

This Subordinate Work Package (SWP) contains procedures for depot level testing of the fuel control assembly used on the Jet Fuel Starter (JFS). Procedures for inspection and repair are contained in SWP 014 01.

Procedures for disassembly, cleaning, and assembly are contained in WP 014 00.

2. SAFETY SUMMARY.

Various steps in this SWP describe physical and chemical processes which may require the use of chemicals, solvents, paints or other commercially available materials. The user of this SWP should obtain the material safety data sheets (Occupational Safety and Health Act (OSHA) Form 20 or equivalent) from the manufacturer or suppliers of materials to be used. The user must become thoroughly familiar with the manufacturer/supplier information and adhere to the procedures, recommendations, warnings, and cautions of the manufacturer/supplier for the safe use, handling storage, and disposal of these materials. The following are general safety precautions and instructions that personnel must understand and apply during many phases of operation and maintenance to ensure personal safety and health, and the protection of DOD property.

2.1 Warning and Caution Statements. WARNING and CAUTION statements have been strategically placed throughout this text prior to operating procedures, practices or conditions considered essential to the protection of personnel (WARNING) or equipment and property (CAUTION). A WARNING or CAUTION will apply each time the related step is repeated. Prior to starting any task, the WARNINGS or CAUTIONS included in the text for that task will be reviewed and understood. Refer to the materials list for materials used in this WP.

2.2 Hazardous Materials Warnings. Hazardous materials warnings in this WP are designed to warn personnel of hazards associated with such items when they come in contact with them during actual use. Detailed explanations of hazardous material symbols used in this WP are pro- vided in WP 002 00. Following are hazardous material warnings used in this work package with explanation for each. Only the warning symbols, however, appear in the task will be reviewed and understood. Refer to the materials list for materials used in this WP.

Lubricating Oil HM1

Lubricating oil may contain tricresylphosphate. This additive is poisonous and can be readily absorbed through the skin. Ensure oil does not remain on ski. Oil may burn if exposed to heat or flames. Neoprene gloves and faceshield/safety goggles will be worn.

Fuel HM2

Fuel is flammable and toxic to eyes, skin, and respiratory tract. Skin/eye protection required. Avoid repeated/prolonged contact. Good general ventilation is normally adequate.

Calibration Fluid

Calibration Fluid is flammable and causes eye and skin irritation. Eye/skin protection required. Avoid repeated and prolonged contact.

3. TESTING.

3.1 General. Testing of the F-15 Jet Fuel Starter (JFS) fuel control shall be performed on test equipment and setup approved by the managing authority of this technical manual. Approved test equipment and setup, including software, will be known as the JFS fuel control test stand. Approval of the test stand shall be documented by suitable means. Documented approval is required after any form, fit or functional changes to the test including software and setup.

3.2 JFS Fuel Control Test Stand Requirements.

a. The standard test stand for the JFS fuel control is part no. 281600-4-1, fuel accessories test stand

(Figure 1, 1). Operation and maintenance of this test set is governed by T.O. 33DA4-6-332-11.

Variations of this test set may be used as approved (refer to paragraph 3.1). T.O. 33DA4-6-332-11 may be supplemented and portions substituted with suitable operational and process documents as required. The approved test stand and operational instructions must be in compliance with all requirements of this work package. Labeling of control function switches shall correspond with labels in this work package. Test setup shall remain as described in this work package.

b. Alternate test stand for the JFS fuel control is part No. 281600-7-1, fuel accessories test stand. Operation and maintenance of this test set is governed by Honeywell document

SE-876-03-1059, Operations and Maintenance Manual. Variations of this test set may be used as approved (refer to paragraph 3.1). SE-876-03-1059 may be supplemented and portions substituted with suitable operational and process documents as required. The approved test stand and operational instructions must be in compliance with all requirements of this work package. Labeling of control function switches shall correspond with labels in this work package. Test setup shall remain as described in this work package.

c. Test stand fluid temperature shall be maintained between 70 and 90 O F (21 and 32

O C) during all procedures, unless otherwise specified.

d. Inlet pressure to the fuel control shall be 25 (±1 psig) during all procedures, unless otherwise specified.

e. Fuel control test setup shall be according to Figure 2. Documented approval of variations may be used in accordance with paragraph 3.1.

f. Simulated differential pressure shall be maintained within limits shown in Figure 3 and

Table 2 for all acceptance testing.

g. During all procedures, check for leakage from fuel control overboard drain port (PDR).

Leakage shall not exceed 1 cc per hour.

3.3 Pump Break-in and Capacity Check. Perform the following break-in and capacity test on new housings and on overhauled housings (any time components of the fuel control pumping section are replaced). Fuel control is not fully assembled for these procedures, however, the fuel control electronics may be installed for these procedures. Refer to instructions in WP 014 00.

During any testing procedure ensure that the pump solenoid is open at all times (unless otherwise indicated) to prevent damage to the components.

CAUTION

a. Install fuel control on test stand as follows:

(1) If required install fuel control speed increaser adapter, part No. 291496-1 and fuel control mounting adapter, part No. 291809-1 or 102187-53-1 on drive pad of test stand (refer to approved operational and process documents).

(2) Install packing, part No. M83248/1-024, on fuel control drive flange.

(3) Install fuel control on mounting adapter, part No. 102187-53-1 and secure with nuts provided with mounting adapter.

(4) Fill fuel control mounting adapter, part No. 291809-1 or 102187-53-1, lubricating oil.

(5) Pressurize mount adapter to 4 (±1) psig (with air).

(6) For new housings, install fuel pump test adapter kit, part No. 296783-1 consisting of part No. 299011-1 Plug Assembly (299087-1 Plug, S9412-

013 Packing), 299012-1 Plug Assembly (299086-1 Plug, S9412-007

Packing, S9412-013 Packing), and 299013-1 Cover Assembly (299088-1

Cover, 299089-1 Plug, S9412-006 Packing, S9412-133 Packing, MS16997-19 Screw), on fuel control and secure with required fasteners, per Figure 4a. Install return fixture part No. 296070-1, bypass valve plug part No. 79001257-1, bellows assembly plug part No. 79001256-1, and scheduling valve plug 79001255-1 as shown in FIG. 4a, sheet 2. Install orifice 367494-1, -2, or -3 to plug port. Install inlet fixture, part No.

102187-53-6 or part No. 291824-1.

(7) For overhauled housings (housings where any components of the fuel control pumping section are replaced): If applicable, disconnect the fasteners holding the governor subassembly in place. Do not disconnect the wires connecting the governor subassembly to the remaining wiring in the fuel control sub-assemblies. Place the governor subassembly in a location where the governor subassembly and the wiring will not be damaged. Install fuel pump test adapter kit, part No. 296783-1 consisting of part No. 299011-1 Plug Assembly (299087-1 Plug, S9412-013

Packing), 299012-1 Plug Assembly (299086-1 Plug, S9412-007 Packing, S9412-013 Packing), and 299013-1 Cover Assembly (299088-1 Cover, 299089-1 Plug, S9412-006 Packing, S9412-133 Packing, MS16997-19

Screw), on fuel control and secure with required fasteners, per Figure 4a.

Install return fixture part No. 296070-1, bypass valve plug part No.

79001257-1, bellows assembly plug part No. 79001256-1, and scheduling valve plug 79001255-1 as shown in FIG. 4a. Install orifice

367494-1, -2, or -3 to plug port. Install inlet fixture, part No. 102187-53-

6 or part No. 291824-1. For refurbished housings having the solenoid attached, do not install shutoff valve cover plug part No. 299012-1. The shutoff solenoid may be used in place of the shutoff valve cover plug.

(8) Service fuel control speed increaser adapter, part No. 291496-1, with lubricating oil SAE 140 or SAE 90.

(9) Connect a line from the test stand fuel inlet connection to PI port on adapter, part No. 102187-53-6 or 291824-1. Cap PR and PJ ports. See

Figure 4.

(10) Connect a line from the return fixture, part No. 296070-1, to test stand fuel outlet and fuel discharge.

b. Perform fuel control break-in per Table 2.

During break-in and pump capacity test, maintain a minimum of 4 (±1) psig inlet pressure at all times to prevent damage to the components. If the fuel control is removed from the test stand or opened, the fuel control must be primed again as described in paragraph 3.4 c.

(1) Repair fuel control if any conditions in break-in could not be met.

(2) Inspect regulating valve filter (Figure 6). If more than 10% of surface area is covered with debris, the filter on the differential pressure valve must be replaced.

Otherwise, replace only the regulating valve filter. Remove electrical solenoid shutoff valve (Figure 6) and clean with isopropyl alcohol and filtered shop air.

Re-install electrical solenoid shutoff valve.

c. Perform pump capacity check as follows:

(1) Operate test stand as required to set speed, inlet pressure, and discharge pressure for each condition of capacity test listed in Table 2. Run each condition for approximately 2 minutes and record fuel flow.

(2) Repair fuel control if fuel flow requirements listed in Table 2 are not met.

d. If fuel control passes pump capacity, check disconnect fuel control from test stand and proceed with assembly. Refer to WP 014 00.

3.4 Installation of Fuel Control onto Test Stand and Preparation for Testing. Install and prepare fuel control for testing as follows:

a. Install fuel control on test stand such that the fuel control is evenly mounted on the test stand fixture and make all connections in accordance with Figure 4 and Figure 2, the approved test stand operational instruction, and the following:

(1) If required install fuel control speed increaser adapter, part No. 29149601, and fuel control mounting adapter, part No. 291809-1 or 1021878-53-1, on test stand drive pad.

(2) Verify condition of packing, part No. M83248/1-024, on fuel control drive flange.

(3) Install fuel control on mounting adapter and secure with nuts provided with the mounting adapter.

(4) Install adapter, part No. 291824-1 or 102187-53-6, on fuel control with three packings, part No. S9412-011, to seal ports.

(5) Fill fuel control mounting adapter, part No. 291809-1 or 102187-53-1, lubricating oil.

(6) Make all test set-up connections. Refer to Figure 4 and Figure 2 and the approved test stand operational instructions.

(7) Pressurize mount adapter to 4 (±1) psig (with air).

b. Set acceleration timer shaft tang engagement as follows (see Figure 5):

(1) Remove locknut.

(2) Turn acceleration time adjustment screw clockwise to its maximum limit

(bottomed out).

(3) Use tool 201414983to measure and record dimension A of Figure 5.

Damage can occur if the acceleration timer adjustment screw is left in the bottomed out position. Do not adjust clockwise from the bottomed out position or the acceleration timer mechanism may be damaged.

(4) Adjust acceleration time adjustment screw as follows:

(a) Add 0.030 inches to dimension A and record as B1. Add 0.070 inches to dimension A and record as B2. Dimensions B1 and B2 will establish the tolerance range for dimension B.

(b) Turn timer adjustment screw counterclockwise approximately 1 and

1/3 turns. Measure and record as dimension B. Ensure dimension b is between the tolerance range established in step (a). Replace locknut.

(c) If dimension B maximum cannot be met, replace governor spring, part

No. 365795-1/-2/-3. Governor spring, part No. 365795-3 is the shortest, part No. 365795-1 is nominal, part No. 365795-2 is the longest. Increasing the length of the spring decreases the amount of

B calibration. If the spring is replaced, repeat steps (1) through (3).

(5) Repeat steps (1) through (3) after any adjustments to the governor, 60 percent governor set point or adjustment screw.

Figure 2. Fuel Control Test Setup Schematic

Symbol Parameter Units

PCD

Control simulated compressor discharge pressure psia

PB Pump inlet pressure psig

PD Pump discharge pressure psig

PI Main filter inlet pressure psig

PJ Control jet boost inlet pressure psig

PR Control manifold pressure psig

Figure 2. Legend

Figure 3. Simulator Differential Pressure Limits

Table 1 . S imulator Di f ferent ia l Pressure Limits

Pressure

, psi Lower

Flow, lb/hr Upper

Flow, lb/hr

30 16 26

40 19 29

56 23 33

66 27 37

76 29 60

80 45 65

90 53 73

100 59 79

200 110 125

300 135 165

400 160 195

500 180 225

600 200 260

700 220 280

*Simulator must be augmented by compressor d ischarge pressure as shown by the pneumat ic regulator .

Table 2. Break-In and Capacity Conditions

Test Title

Speed

(rpm ±10)

Inlet

(psig ±5)

Discharge

(psig)

Required Time in Minutes

Actual Fuel

Time in Minutes

Required Fuel Flow (pph mini-mum)

Actual Fuel Flow (pph)

Break-In

Capacity

10,000

10,000

10,000

Figure 4. Fuel Control Connections and Ports

Figure 4a. Fuel Control Housing Test Set-up (Sheet 1 of 2)

Figure 4a. Fuel Control Housing Test Set-up (Sheet 2 of 2)

Figure 5. Measurement of Fuel Control Acceleration Timer Shaft Tang Engagement

c. Prime fuel control as follows:

WARNING

Loose fittings can cause fluids to spray which may be hazardous to skin and eyes. Wear face shield and gloves to limit contact.

(1) Slightly crack fittings on control manifold pressure port (PR), bleed port, and pump discharge port (PD). See Figure 4.

(2) Supply 2 psig fuel inlet (PI) pressure.

(3) When leakage comes from each port wait for 20 seconds. If fuel does not come from a port, leave that port open as other ports are closed, enabling fuel pressure to increase and fuel to flow to each cavity. Maintain this until fuel with no air bubbles is flowing from the ports.

(4) Close each fitting and turn off fuel inlet.

4. ACCEPTANCE TEST

4.1 Fuel Control Adjustment and Acceptance Test. Test JFS fuel control to conditions in Table 3 and as follows (refer to Figure 2 for setup):

NOTE

Final acceptance test (all data points) shall be accomplished with all adjustments set and lockwired as required. Until final acceptance test Operator may use individual test points only as needed to set fuel control for final acceptance test and troubleshoot.

NOTE

Close Overboard Bypass Valve and open Inlet Bypass Valve. If the fuel control is removed from the test stand or opened, the fuel control must be primed again as described in 3.4 c.

4.1.1 Fuel Control Preset Conditions

a. Set PO to 300 (+/-10) psig. Disconnect the PCD supply. Set to conditions of Table 3, data point

10. Remove the preload on the schedule valve bellows by unscrewing the PCD stem (located inside the PCD fitting). This will be accomplished when the discharge flow stops decreasing.

Reconnect the PCD line. Apply conditions of Table 3, data point 10. Set the Wf to the limits in

Table 3, data point 10 by adjusting the acceleration schedule. To make this adjustment, loosen the two screws holding the schedule valve and rotatevalve clockwise, which will increase the flow. A counterclockwise adjustment will decrease the flow. Tighten the two screws. Reference Data

Point 10.

b. Disconnect PCD supply. Set to conditions of Table 3, data point 5. Reconnect PCD supply.

c. Verify conditions of data point 10.

d. If adjustments are made verify Data Point 5.

Use hex head wrench to secure set screw while adjusting governor setting during operation.

e. Accelerate fuel control to 9900 (+/-50) rpm. Apply 55 +/- 1.0 psia PCD. Set Wf using 100 percent governor adjustment to 160 (+/-10) lb/hr.

f. Verify proper governor operation by slowly increasing the speed by approximately 50 rpm from the governor set point. Verify that the fuel flow decreases. Return rpm to governor set point.

Slowly decrease speed approximately 50 rpm. Verify that fuel flow increases.

g. Decrease fuel control speed to 5900 (+/-25) rpm. Apply 22 (+/-1) psia PCD. Set Wf using 60 percent governor adjust to 55 (+/-5).

h. Verify proper governor operation by slowly increasing the speed by approximately 50 rpm from the governor set point. Verify that the fuel flow decreases. Return rpm to governor set point.

Slowly decrease speed approximately 50 rpm. Verify that fuel flow increases.

4.1.2 Deceleration Schedule Adjustment (Minimum Wf)

a. Set fuel control to first operating conditions in Table 3, Data Point 1. Record deceleration Wf.

Wf must be within limits in Table 3.

b. Set fuel control to second operating conditions in Table 3, Data Point 1. Record deceleration

Wf. Wf must be within limits in Table 3.

c. If deceleration Wf is not within limits in Table 3, Data Point 1, select and install appropriate flow control orifice, part No. 3883827-1/-2/-3 (Figure 2, 130, sheet 3, WP 014 00) to get Wf within limits.

4.1.3 Overspeed Check

a. Set fuel control to operating conditions of Table 3, Data Point 16.

b. Open Overspeed Bypass Valve. Record Wf. Wf must be within limits in Table 3.

4.1.4 Governor 100-Percent Speed Adjustment

c. Set fuel control to operating conditions in Table 3, data point 18. Record Wf. Temperature must be within limits in Table 3.

Note After final adjustment, the governor jam nuts must have full engagement with adjustment screw and sleeve.

d. If Wf is out of limits, adjust 100% Governor Adjust (Figure 4) until Wf is within limits in Table

3. Ensure that dimension B is within limits.

4.1.5 Pressure Switch Actuation Point

a. Connect a clean filtered supply of either lubrication oil or air to the pressure switch fitting and make electrical connection to supply 28 (+/-2) Vdc and read switch activation/deactivation.

b. Set fuel control to operating conditions in Table 3, Data point 27.

c. Slowly decrease pressure until the switch deactivates. Deactivation pressure shall be within

Table 3 limits.

d. Slowly increase pressure (oil or air) to the switch until switch activates. Activation pressure shall be within Table 3 limits. Remove oil/air supply and disconnect pressure switch electrical connection.

4.1.6 Governor 60-Percent Speed Adjustment

a. Set fuel control to operating conditions in Table 3, Data Point 17. Record Wf and temperature.

Wf and temperature must be within limits in Table 3.

After final adjustment, the governor jam nuts must have full engagement with adjustment screw and sleeve.

b. If Wf is out of limits, adjust 60% Governor Adjust (Figure 4) until Wf is within limits in Table

3. Ensure that dimension B is within limits.

4.1.7 Acceleration Limiter Schedule (Refer to Figure 7)

a. Set fuel control to the operating conditions in Table 3, Data Point 25 and Data Point 26.

Remove pressure from pressure switch. Fuel flow shall begin to fall within 1.5 seconds after pressure is removed.

b. Reapply pressure to pressure switch within 5 to 15 seconds. Fuel flow shall return to 100 percent within 8 to 12 seconds after pressure is reapplied.

c. If acceleration or deceleration is not within limits, adjust acceleration timer (Figure 4) until limits specified in Table 3 are met. If adjustments are made ensure dimension B is still within limits.

4.1.8 Start Fuel Flow Adjustment

a. Set the fuel control to operating conditions of Data Point 2 of Table 3 and ensure that the minimum flow is met. Record min Wf.

b. Set fuel control to operating conditions in Table 3 Data Point 3. Record Wf. Wf must be within limits of Table 3.

c. Set fuel control to operating conditions in Table 3, Data Point 4. Record Wf. Wf must be within the limits in Table 3.

d. Set fuel control to operating conditions in Table 3, Data Point 5. Record Wf. Wf must be within limits in Table 3.

e. If Wf is not within limits in Table 3 for Data Points 3, 4 or 5, adjust the start Wf as follows:

(1) Set fuel control to operation conditions in Table 3, Data Point 5.

(2) Disconnect PCD line (Figure 2). Locate adjustment screw (Figure 2, 119 sheet 3 WP

01400) in the inside diameter of PCD fitting. Adjust screw to obtain the Wf required in

Table 3, Data Point 5.

Adjustment screw must be in contact with bellows without PCD line connected to maintain proper setting after reconnecting PCD line. To ensure contact, approach set point from a lower setting. If flow will not lower from required set point, reject fuel control.

(3) Run fuel control for 3 minutes and check for fuel leakage from PCD fitting. If leakage occurs, reject fuel control for bellows failure.

(4) Reconnect PCD line. Wf must remain within limits of Table 3 for Data Point 5.

(5) Verify that Wf for Data Points 3 and 4 are within Table 3 limits.

4.1.9 Lower Acceleration Schedule Adjustment

a. Set Fuel Control to operating conditions in Table 3, Data Point 6. Record Wf. Wf must be within limits in Table 3.

b. Set fuel control to operating conditions in Table 3, Data Point 7. Record Wf. Wf must be

4.1.10 Scheduling Valve Hysteresis

a. Set fuel control to operating conditions in Table 3, Data Point 8, (a). Record Wf.

b. Increase PCD 10 psi above value set for (a) and set fuel control to operating conditions in

Table 3, Data Point 8, (b). Record Wf.

c. Decrease PCD and set fuel control to operating conditions in Table 3, Data Point 8, (c). Record

Wf.

d. Calculate and record hysteresis by subtracting Wf of (a) from Wf of (c). Maximum of 10.

4.1.11 Back Pressure Sensitivity

Do not run high PD for extended periods of time.

a. Set fuel control to operating conditions in Table 3, Data Point 9. Close inlet bypass valve

(Figure 2). Record Wf and PD for (a).

b. Increase back pressure until PD increases 50 psi. Record Wf and PD for (b).

c. Wf shall not change more than the sensitivity limits in Table 3, Data Point 9.

d. Open inlet bypass valve.

4.1.12 Upper Acceleration Schedule Adjustment

a. Set fuel control to operating conditions in Table 3, Data Point 10. Record Wf. Wf must be

b. Set fuel control to operating conditions in Table 3, Data Point 11. Record Wf. Wf must be

c. Set fuel control to operating conditions in Table 3, Data Point 12. Record Wf. Wf must be

d. Set fuel control to operating conditions in Table 3, Data Point 13. Record Wf. Wf must be

e. If Wf is not within limits in Table 3 for Data Points 6, 7, 10, 11, 12, and 13 of the Lower and

Upper Acceleration Schedule, adjust the acceleration schedule as follows:

(1) Set fuel control to operation conditions in Table 3, Data Point 10.

(2) Locate acceleration schedule adjustment (Figure 2). To increase schedule level, loosen the two screws holding the scheduling valve and rotate clockwise. To decrease level, rotate counterclockwise. Adjust to obtain the Wf required in Table 3, Data Point 10.

Acceleration solenoid must be energized.

(3) If adjustment fails to achieve Wf within limits, return fuel control to assembly for a bellows rate spring adjustment (part no 365775-1 or part No. 365776-1, Figure 2, 126, sheet 3, WP 014 00). To increase schedule level, install a lower rate spring. To decrease schedule, install a higher rate spring.

(4) Verify Wf for Data Points 6, 7, 11, 12, ad 13 are within limits of Table 3.

4.1.13 Overboard Fuel Bypass

Close Inlet Bypass Valve and open Overboard Bypass Valve and Backpressure Valve to bleed off pressure before proceeding.

a. Set operating conditions per Data Point 14. Adjust backpressure to obtain 280 psig on pump discharge. Wf must be within the limits of Data Point 14. Use any one of the three cover assemblies (P/N 365809-1,-2,-3) to obtain the required flow.

b. The fuel control must provide 175 lb/hr minimum Wf while running at condition of Data Point

15. If the unit does not meet these requirements reject the fuel control.

Close Overboard Bypass Valve and open Inlet Bypass Valve.

4.1.14 Shutdown Solenoid Current

a. Set fuel control to operating conditions in Table 3, Data Point 20.

b. Vary solenoid voltage and record current required to energize and de-energize solenoid.

Current draw shall be within limit of Table 3.

c. Perform Leak Check as specified in Table 3, Data Point 20.

Close Overboard Bypass Valve and close Inlet Bypass Valve

4.1.15 Check Valve Assembly

a. Check crack pressure and leakage of bypass check valve assembly as shown in Figure 4 (Fuel

Bypass Port).

b. Disconnect fitting from the bypass port and apply fuel pressure until bypass check valve opens and record crack pressure.

c. Crack pressure and leakage must be within limits specified in Table 3, Data Point 24.

4.1.16 Dynamic Shaft Seal

a. Supply oil to the drive unit shaft compartment at a pressure of 4 (+/-1) psig.

b. Operate fuel control for at least 5 minutes at the operating conditions in Table 3, Data Point 19.

Check and record leakage from the overboard drain. Maximum leakage allowed is 1 cc per hour

(2 drops per 5 minutes) oil or fuel.

4.1.17 Leak Check

a. Cap off all ports or close all valves except the PCD bellows fitting and connect the inlet fuel supply to the fuel control port PB. See Figure 4. Operate fuel control at the conditions in Table 3, Data Point 21. No leakage is allowed from fuel control drain, mating flanges, housing walls or

PCD fitting.

b. Remove cap from port PR. Apply 5 (+/-1) psig to PB port and energize shutoff solenoid (28

Vdc to pins A(-) and C(+)) until fuel flows out of port PR. De-energize solenoid and allow system to stabilize for approximately 5 minutes. Leakage shall be within Table 3 limits. Apply 30

(+/-5) psig to PB port. Record leakage. Table 3 Data Point 22.

c. Any flange or housing wall leakage that exceeds maximum specified shall be cause for rejection. Table 3 Data Point 23.

5. TROUBLESHOOTING

A table of troubleshooting procedures, Table 4, is provided to identify malfunctions, isolate the cause of the malfunction, and recommend corrective action. The isolation procedures covered in this SWP pertain to malfunctions which may arise within the fuel control only. Simply and easily diagnosed problems, such as broken wires, loose connections, and obvious damage, are not included. The procedures are arranged according to the logical order in which checks would be made. Each isolation procedure indicates the corrective actions or an alternate corrective action until the final resolution of the problem is accomplished.

Figure 6. Fuel Control Fuel System Schematic

Table 3. Fuel Control Acceptance Test Data Sheet

Table 3. Fuel Control Acceptance Test Data Sheet (cont.)

Table 3. Fuel Control Acceptance Test Data Sheet (cont.)

Figure 7. Acceleration Schedule Chart

Figure 8. Deleted

Figure 9. Deleted

Figure 10. Deleted

Figure 11. Deleted

Figure 12. Deleted

Figure 13. Deleted

6. POST TEST PROCEDURES.

6.1 Preservation and Removal from Test Stand.

Preserve the fuel control for shipment or storage in accordance with T.O. 2J-1-18 and as follows:

If fuel control is to be installed on a JFS within 10 days after testing, fuel control does not require preservation.

a. Close all air and fuel shutoff valve on test stand.

b. Disconnect all air and fuel lines from fuel control and adapter.

c. Connect suitable lines to PD and PR ports (Figure 4) and place other end of hose lines in a container.

d. Connect a source of lubricating oil, Specification MIL-L-6081 Grade 1010, to PB port (Figure 4).

e. Operate test stand as required to drive fuel control at a speed of 750 (±250) rpm until clean lubricating oil flows from PD and PR ports. Shutdown test stand.

f. Remove fuel control from test stand.

g. Drain excess lubricating oil from fuel control.

6.2 Final Assembly and Preparation for Shipment

a. Install shipping covers in or on all fuel control openings.

b. Ensure all lockwire is installed where required and clean lubricating oil and fuel off surfaces with a clean, dry rag.

Table 4. Troubleshooting

Table 4. Troubleshooting (cont.)

Table 4. Troubleshooting (cont.)