250-c20 CSL-1009

COMMERCIAL
l

SERVICE

LETTER

\/ Dy%mit Diesel Allison i

Indianapolis. Indiana 46206

Pagelof 11 January 20, 1972 FAA-DER Approved SUBJECT: Early Lightoff or Afterfire

During engine startup or shutdown, some operators have experienced an early lightoff or afterfire with the twist grip in FUEL OFF and under boost As a result, some engines exceeded TOT limits, which pump pressure. requires a mandatory inspection or turbine change. To avoid a mandatory engine inspection or turbine change, this CSL revises the regular shutdown procedure which will be included in the next 250-C.20 Operation and Maintenance Manual revision. It also provides maintenance action intended to prevent an early lightoff or afterfire caused by (1) the fuel control not in cutoff and/or (2) a worn fuel cutoff valve,. SHUTDOWN: 1. In addition to the regular Flight Manual procedure, monitor your instruments to insure that engine shutdown has actually occurred. CAUTION TO ASSURE THROTTLE CUTOFF, HOLD TWIST GRIP IN CLOSED POSITION UNTIL THE Nl DECELERATES TO ZERO AND TOT IS STABILIZING. 2. INSPECTION SCHEDULE: Check for TOT decrease, Component New fuel controls which have accumulated 1-25 hr. Fuel controls which have accumulated more than 25 hr. EFFECTIVITY: etc. Time Before next days flight; repeat at 50-hr intervals until control is repaired. Within next 50 flight-hr ; repeat at 50-hr intervals until control is repaired.

All fuel control assemblies prior to and including S/N lAAC284 and S/N lAAC328 thsough lAAC359.

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250-c20 CSL-100: Pll,? 2

FUEL CONTROL QUADRANT CHECK:

1.

Check fuel control quadrant reading. It must be 0 to minus 2 with throttle lever against min. stop when the twist grip is in FUEL OFF. If the quadrant reading exceeds 0, readjust the minimum stop on the fuel control to 0 to minus 2 on the fuel control quadrant. The minus 2 position may be obtained by adjusting the minimum stop screw to O, then out one-half turn from the 0 position. Check the quadrant to be sure the pointer is at 0 to minus 2 when the twist grip is in FUEL OFF. Disconnect ignition lead from igniter (refer to 250-C20 Operation and Maintenance Manual). CAUTION Do NOT ENERGIZE IGNITION EXCITER WHILE THE SPARK IGNITER IS DISCONNECTED.

2.

FUFLCUTOFF VALVE OPERATIONAL CHECK:

1.

2. 3. 4. 5.

Disconnect the flexible line from the fuel nozzle and place the free end in a suitable container. Turn on the aircraft switches required to provide fuel boost pump pressure to the engine. Rotate the twist grip toward IDLE, then return it to FUEL OFF. If fuel flows from the flexible line, or exceeds 20 drops per min., with the twist grip in FUEL OFF, you have a worn cutoff valve requiring repair. NOTE Repeat this check at least twice before accepting or repairing the fuel control

6.

If the fuel cutoff valve operates satisfactorily, connect the fuel line and ignition lead (refer to the 250-C20 Operation and Maintenance Manual).

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250-c20 CSL-1009 Page 3 FUEL CONTROL REPAIR: These instructions apply to Model M,C-40 Fuel Controls serial numbers up to and including lAAC284 and lAAC328 through lAAC359 which have not pre,viously been reworked and identified in accordance with the instructions herein. NOTE Controls reworked to these instructions are marked with the letter S stamped in the upper right-hand corner of the nameplate. Do not start repairing fuel controls until the special tools and replacement parts defined i.n this CSL are available from your distributor. PERSONNEL REQUIREMENT: The assembly and disassembly o? the fuel control covered in these instructions must be accomplished by a qualified fuel system technician to insure that internal control settings are not disturbed during part removal and replacement. The rework of the fuel control housing covered in these instructions must be accomplished by a qualified mechanic or maaist to prevent damage which would require replacement of the main bousing. FACILITY REQUIREMENTS: TOOL REQUIREMENTS: The work covered in these instructions must be performed in a clean environment to prevent any contamination from entering the control. Two special tools or their equivalent are required follows: STD 67298 Chamfer Tool, as

Shut Off Port (Figure 1)

Required to incorporate a 0.006-o. 010 inch x 45 chamfer on the fuel outlet passage in the main housing. STD 67299 Stick, Chamfer Blending (Figure 2) a light blended edge on the chamfer.

Required to incorporate

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STD

67298 ALTERNATE DESIGN STD 67298 AN 0 0 ?

MODIFIED REAMER

ADJUSTABLE HANDLE

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REAMER

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0.010 GAP 0.006 WITH SHARP EDGE ONEDGEOFPORT

1
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MODIFIED

ADJUSTABLE STOP

BUSHING

GUIDE I

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F
HOUSING PORT REWORKOFFUELOUTLETPORT USING CHAMFER TOOL FIGURE 1

-FUEL OUTLET REWORK THIS SHARP EDGE TO 0.006 - 0.010 BY 45 CHAMFER

NOTE:

IF EDGE APPEARS CHAMFERED INSTALL TOOL STD 67298 ON A TEST PIECE WHICH HAS 0.279 - 0.281 DIAMETER HOLE WITH SHARP EDGE AND SET 0.006 - 0.010 INCH GAP PRIOR TO REWORKING HOIJSING

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250-C20 CSL-1009 Page 6 NEW PART REQUIREMENTS: Part No. 93393 78109-024 78109-007 78147-008 MS24665-151 PROCEDURE: 1. Disassembly 1.1 1.2 Remove lockwire from the three screws (30, 31, 32, Figure 3) which secure the cutoff valve cover (29, Figure 4). Remove nuts (4, 6, Figure 4), washer (7), and cutoff lever (9). CAUTION DO NOT LOOSEN POSITIONING NUTS (20, 37, 38, FIGURE 3) ON CONNECTING LEVER (22). 1. 3 1. 4 1.5 1.6 Remove cotter pin (18) and spring (19). Position control so that cutoff valve cover (29, Figure 4) is facing upward. Remove three screws (30, 31, 32, Figure 3) and washers (33). Using a suitable tool, push down on cutoff cam and shaft assembly and carefully remove cover (29, Figure 4) without moving or rotating the cam and shaft assembly. CAUTION CUTOFF CAM AND SHAFT ASSEMBLY MUST BE LEFT IN ITS CORRECTLY INSTALLED POSITION AS THE COVER IS REMOVED. NOTE Before removing, note installed position of valve (12, Figure 4) to insure correct installation at reassembly. During all subsequent work, the cutoff cam and shaft assembly must not be rotated. Nomenclature Cutoff Valve Packing Pat king Packing for shaft assy Cotter Pin Qty 1 1 1 1 1

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2x-c20 Page 7

CSL-1009

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250-C20 CSL-1009 l'iqe 8

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250-C20 CSL-1009 Pa.ge 9 1. 7 1. 8 1. 9 Remove ball (10, Figure 4) and spring (11). Carefully remove lockwire and cutoff valve (12). and screw (13), (cutoff link (14),

Discard cutoff valve (12) and packings (2, 3). NOTE -Only replace packing (15) if damaged to mini.mize the possibility of inadvertent rotation of shaft (16).

2.

Rework
2.1

fnspect the edge of the fuel outlet port to insure that it is sharp and not already chamfered with the top edge of the chamfer lightly polished and blended. NOTE The following instructions have sharp edges. apply to fuel outlet ports which

If any doubt exists on the condition of the edge of the fuel outlet port, tool STD 67296 can be adapted as shown in Figure 1 and used to insure that the proper edge conditions as defined in this CSL are met. 2.2 Place tool STD 67298 on the outlet port. Measure the gap between the tool bushing and tool stop as sho.wn in Figure 1. This gap should be 0.006-o. 010 inches as measured with a feeler gage. Adjust the tool stop if required to obtain a 0.006-o. 010 inch gap. After the proper gap has been obtained, machine a 0.0060.010 inch chamfer on the outlet port by turning the tool reamer clockwise until the tool stop just cornacts the tool guide.

2.3

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250~czcl CSL-1009 Page 10 2. 4 Using Chamfer Blending Stick STD 67299, very lightly blend the edge of the chamfer as shown in Figure 2. CAUTION BEFORE USING STICK STD 67299, INSURE THAT THE 120 BLENDING FACE ON THE END OF THE STICK IS FLAT AND NOT GROOVED FROM PREVIOUS USE. REDRESS THE STICK IF REQUIRED SO THAT THE REQUIREMENTS SHOWN ON FIGURE 2 WILL BE MET. 2. 5 2.6 3. Clean the face of the housing and the bore of the outlet port with compressed air. Treat the reworked edge of the port with Alodine.

Assembly 3. 1 Install new cutoff valve (12, Figure 4) into cutoff link (14) and secure to shaft assembly (16) with screw (13). Torque to 4 to 6 lb. in. and lockwire using MS20995C20 wire (0.0190.02 1 inch diameter). Install new packing (15) on shaft (16) only if old seal is damaged. Install spring (11) and ball (10) in end of cutoff valve (12). Install new packings (2,3) to cover assembly (29) and install cover assembly to fuel control. Caution must be taken not to dislocate ball (10) or to ratate shaft (16). NOTE Apply a light coat of Petrolatum, Federal Specification VV-P-236 to all three packings to assist reassembly. 3. 5 Secure cover assembly to the control with three screws (30,31,32, Figure 3) and washers (33). Torque screws to 26 to 32 lb. in. Install spring (19, Figure 3) and cotter pin (18). cotter pin. Bend

3.2 3.3 3.4

3.6

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250-c20 CSL-1009 Page 11 3.7 Install cutoff lever (9, Figure 4) and secure with nuts (4,6) and one washer (7). Torque nut 4 to 18 to 22 lb. in. and nut 6 to 8 to 12 lb. in. Lockwire three screws using wire MS20995EY20.

3.8 3.9

To compensate the setting of the shutoff valve for the chamfer added to the fuel outlet port, turn nut (37, Figure 3) closest to the throttle shaft 2//3 of one turn (4 flats only) towards the throttle shaft. Then turn the outboard nut (38) the same amount in the same direction to lock the shutoff valve linkage. After the nuts have been repositioned, lightly stake the threads on the link (22, Figure 3) adjacent to the nuts to prevent movement of each nut. CAUTION LINK (22) MUST BE SUPPORTED DURING STAKING OF THE THREADS.

3.10

4.

Identification 4. 1 4.2 Mark controls reworked to these instructions, with an S stamped in the upper right-hand corner of the nameplate. Record the Serial Number of the repaired fuel control in the White Pages, Part HI of the Engine Log Book:.

5.

Installation 5. 1 5.2 Reinstall the repaired fuel control (refer to tlhe 250-C20 Operation and Maintenance Manual). After the control has been repaired, perform the fuel cutoff valve operational check to insure that fuel shutoff occurs.

d. 0. Davidson, Manager Aerospace Service

MJK/mjp

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