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CT7-TP 9 MAINTENANCE MANUAL Revision No.

51 Dated 10/31/2002
MM 73-00-00
FUEL SYSTEM - TEST
Page Block Effectivity: * * * FOR ALL CT7-9 MODELS
1. General Information.
This section provides instructions for testing fuel system components.
2. Tools, Equipment, and Materials.
NOTE: You can use equivalent alternatives for Tools, Equipment, and Consumable
Materials.
A. Tools and Equipment.
(1) Special Tools. None.
(2) Standard Tools.

Description Manufacturer
Ohmmeter Local Purchase
Test Light Local Purchase

(3) Locally Manufactured Tools.

Tool No. Nomenclature


LMT-767 Fitting, Pressure Test (Figure 501)
LMT-803 Retainer, Fuel Injector Test Plug Assembly
(Figure 502)
LMT-804 Clamp Assembly (Figure 503)
LMT-805 Adapter, Pressure Test Fitting (Figure
504)
LMT-912 Adapter, Fuel Injector Tip Shroud Air
(Figure 505)
LMT-964 Tool, Spring Retainer Removal/Installation
(Figure 506)

B. Consumable Materials.

Description Manufacturer
Caps, Protective Protective Closures Co., Inc.
2166 Elmwood Avenue
Buffalo, NY 14207
USA
Fluid, Calibrating Type II (MIL- Local Purchase
C-7024)
Fuel, Turbine Refer to INTRODUCTION for the approved type of
• Jet A (ASTM D1655) fuels and suppliers.
• JP-5

Gloves, Thermally Insulated Local Purchase


Nitrogen, Bottle Local Purchase
Plugs, Protective Protective Closures Co., Inc.
2166 Elmwood Avenue
Buffalo, NY 14207
USA
Solvent, Trichloroethane (O-T- Local Purchase
620)

GE PROPRIETARY INFORMATION - Not to be used, disclosed to others or


Date Printed: reproduced without the express written consent of GE. Technical data is Page
Sep 8, 2009 considered ITAR and/or EAR controlled; transfer of this data to a Non-US 1 of 19
Person, without USG authorization, is strictly prohibited.
CT7-TP 9 MAINTENANCE MANUAL Revision No. 51 Dated 10/31/2002
MM 73-00-00
FUEL SYSTEM - TEST
Page Block Effectivity: * * * FOR ALL CT7-9 MODELS

Tape, Electrical 1-inch (25 mm) Local Purchase


wide

C. Expendable Parts.

Part No. Nomenclature

NOTE: Preformed packings can be obtained from:


GE Aircraft Engines
CT7 Turboprop Product Support Eng.
1000 Western Avenue
Mail Zone 24020
Lynn, MA 01910
USA

M83248/1-003 Packing, Preformed


M83248/1-004 Packing, Preformed
M83248/1-009 Packing, Preformed

D. Referenced Procedures.

ATA No. Description


- - Introduction
70-42-00 Blending and Removal of High Metal Procedures
73-00-00 Cleaning
73-00-00 Inspection
73-00-00 Repair 004
73-00-00 Repair 012

3. Pressure-Test of Overspeed and Drain Valve Manifold, Main Fuel Feed Tube, Main Fuel
Manifold, HMU-to-AGB Drain Tube, and AGB-to-HMU Hose Assembly.
A. If tube assembly has been repaired or if Leaks are suspected, pressure-test tube
assemblies as follows:
WARNING: CALIBRATING FLUID
MIL-C-7024
• COMBUSTIBLE - DO NOT USE NEAR OPEN FLAMES, NEAR WELDING AREAS, OR ON HOT
SURFACES.
• PROLONGED CONTACT WITH SKIN MAY CAUSE IRRITATION. PROLONGED INHALATION OF
VAPOR CAN CAUSE DIZZINESS, HEADACHE, AND INTOXICATION.
• IF THERE IS ANY PROLONGED CONTACT WITH SKIN, WASH AFFECTED AREA WITH SOAP
AND WATER. IF LIQUID CONTACTS EYES, FLUSH EYES THOROUGHLY WITH WATER. REMOVE
SOLVENT-SATURATED CLOTHING. IF VAPORS CAUSE LIGHT-HEADEDNESS, GO TO FRESH
AIR. IF LIQUID IS SWALLOWED, DO NOT TRY TO VOMIT. GET MEDICAL ATTENTION.
• WHEN HEATED, HOT FLUID MAY CAUSE BURNS. AVOID CONTACT WITH HOT FLUID. IF
SKIN CONTACTS HOT FLUID, FLUSH AFFECTED AREA WITH COLD WATER FOR 10 MINUTES.
SEEK MEDICAL HELP IMMEDIATELY.
• WHEN HANDLING OR WHEN APPLYING LIQUID AT AN AIR-EXHAUSTED WORKBENCH, WEAR
APPROVED GLOVES AND GOGGLES (OR FACE SHIELD).

GE PROPRIETARY INFORMATION - Not to be used, disclosed to others or


Date Printed: reproduced without the express written consent of GE. Technical data is Page
Sep 8, 2009 considered ITAR and/or EAR controlled; transfer of this data to a Non-US 2 of 19
Person, without USG authorization, is strictly prohibited.
CT7-TP 9 MAINTENANCE MANUAL Revision No. 51 Dated 10/31/2002
MM 73-00-00
FUEL SYSTEM - TEST
Page Block Effectivity: * * * FOR ALL CT7-9 MODELS

• WHEN HANDLING OR WHEN APPLYING LIQUID AT AN UNEXHAUSTED WORKBENCH, WEAR


APPROVED GLOVES, GOGGLES (OR FACE SHIELD) AND APPROVED RESPIRATOR.
• DISPOSE OF LIQUID-SOAKED RAGS IN APPROVED METAL CONTAINER.
(1) Flush the tube assembly thoroughly with calibrating fluid.
WARNING: HIGH PRESSURE TESTING
• HIGH PRESSURES USED DURING TESTING MAY CAUSE RUPTURING OR BURSTING OF FAULTY
TUBES AND HOSES. THE RESULT COULD BE SERIOUS INJURY.
• TO PREVENT INJURY, COVER ALL TUBES AND HOSES WITH A SUITABLE SAFETY SHIELD
DURING TESTING.
• WHEN CAPS OR PLUGS ARE USED, BE SURE THEY ARE SECURELY INSTALLED TO PREVENT
THEM FROM BEING BLOWN OUT.
• BE SURE THAT PRESSURES ARE BLED OFF BEFORE EXPOSING OR TOUCHING HOSES OR
TUBES.
(2) Restrict one end of the tube assembly, and using calibrating fluid build up
pressure within the tube to applicable test pressure (table 501). Maintain the
specified test pressure for a minimum of 2 minutes. Leakage or a decrease in
pressure is not permitted.
TABLE 501. PRESSURE TEST PARAMETERS FOR TUBES
Nomenclature Test Pressure

Overspeed and Drain Valve Manifold 400 psig (2758 kPa)


Main Fuel Feed Tube, Main Fuel Manifold, 800 psig (5516 kPa)
and HMU-to-AGB Drain Tube
AGB-to-HMU Hose Assembly 400 psig (2758 kPa)

B. If the tube fails the test because of high metal on the sealing surfaces, then
blend the high metal (GEK 9250, 70-42-00); otherwise, the tube is not repairable.
Replace defective tube.
WARNING: TRICHLOROETHANE
O-T-620
• DO NOT USE NEAR OPEN FLAMES, WELDING AREAS, OR ON VERY HOT SURFACES. DO NOT
SMOKE WHEN USING IT. HEAT AND FLAMES CAN CAUSE THE FORMATION OF PHOSGENE GAS
WHICH IS INJURIOUS TO THE LUNGS.
• REPEATED OR PROLONGED CONTACT WITH LIQUID OR INHALATION OF VAPOR CAN CAUSE SKIN
AND EYE IRRITATION, DERMATITIS, NARCOTIC EFFECTS, AND HEART DAMAGE.
• AFTER PROLONGED SKIN CONTACT, WASH CONTACTED AREA WITH SOAP AND WATER. REMOVE
CONTAMINATED CLOTHING. IF VAPORS CAUSE IRRITATION, GO TO FRESH AIR. GET MEDICAL
ATTENTION FOR OVEREXPOSURE OF SKIN AND EYES.
• WHEN HANDLING LIQUID IN VAPOR-DEGREASING TANK WITH HINGED COVER AND AIR
EXHAUST, OR AT AIR-EXHAUSTED WORKBENCH, WEAR APPROVED GLOVES AND GOGGLES.
• WHEN HANDLING LIQUID AT OPEN, UNEXHAUSTED WORKBENCH, WEAR APPROVED RESPIRATOR,
GLOVES, AND GOGGLES.
• DISPOSE OF LIQUID-SOAKED RAGS IN APPROVED METAL CONTAINER.
C. Using trichloroethane, pressure-flush tube assembly in both directions. Cap all
inlets immediately after flushing.
4. Functional Test of Fuel Pressure Switch.
A. With fuel pressure switch connected to a pressure test stand, connect a test light
or meter to pin 2 and pin 3 in the electrical connector. Light must be ON and
GE PROPRIETARY INFORMATION - Not to be used, disclosed to others or
Date Printed: reproduced without the express written consent of GE. Technical data is Page
Sep 8, 2009 considered ITAR and/or EAR controlled; transfer of this data to a Non-US 3 of 19
Person, without USG authorization, is strictly prohibited.
CT7-TP 9 MAINTENANCE MANUAL Revision No. 51 Dated 10/31/2002
MM 73-00-00
FUEL SYSTEM - TEST
Page Block Effectivity: * * * FOR ALL CT7-9 MODELS

there must be a continuity between pin 2 and pin 3 at 0 psig (0 kPa).


B. Increase pressure gradually to 50 psig (345 kPa) maximum. No Leaks are allowed.
Circuit resistance between pin 2 and pin 3 must be 0 ohms.
C. Gradually decrease pressure until circuit closes (light goes ON or meter reads
continuity). This must occur at 8-9 psig (55-62 kPa).
D. Slowly increase pressure, circuit must open (light goes OFF or meter reading is a
minimum of 30 megohms) at no more than 2 psig (14 kPa) above the actual closing
pressure.
E. At 0 psig (0 kPa) with 50 V dc applied, check insulation resistance between:
pin 2 to pin 1
pin 3 to pin 1
pin 2 to body
pin 3 to body
pin 1 to body
Resistance should be a minimum of 30 megohms.
F. If fuel pressure switch fails any of the above tests, replace the switch.
5. Pressure-Test of Fuel Injectors PN 5051T35.
CAUTION: • PRODDING THE FUEL INJECTOR FROM THE TIP IS NOT ALLOWED. THIS COULD CAUSE
EXCESSIVE FUEL FLOW FROM THE FUEL INJECTOR AND SEVERE ENGINE DISTRESS DURING
ENGINE OPERATION.
• DO NOT DAMAGE INLET FITTING OF FUEL INJECTOR DURING REMOVAL OF SPRING RETAINER.
• DO NOT USE NEEDLE NOSE PLIERS TO REMOVE THE SPRING RETAINER. DAMAGE TO THE FUEL
PASSAGE OF THE FUEL INJECTOR CAN OCCUR.
• DAMAGE TO FUEL INJECTOR ID OR HIGH METAL WILL MAKE REMOVAL OF FUEL FILTER
DIFFICULT.
NOTE: This pressure-test is required for all fuel injectors that have had tip
misalignment corrected (73-00-00, REPAIR 004).
A. Remove spring retainer (1, Figure 507) and fuel filter (2) from the fuel injector
inlet fitting as follows:
(1) Use the flat end of the spring retainer removal/installation tool LMT-964
(Figure 507), and pry gently clockwise under the stem of the spring retainer
(1), and lift the spring retainer out of the fuel injector inlet fitting.
(2) Insert a small hole gage (0.105-0.154 inch (2.7-3.9 mm) diameter) into the
inside diameter of the fuel filter (2). Expand the gage to grasp the fuel
filter and gently pull out the filter.
CAUTION: DO NOT USE FORCE TO PULL OUT THE FUEL FILTER. DAMAGE TO THE FUEL INJECTOR
INLET FITTING CAN OCCUR.
(3) If the fuel filter (2) does not come out easily, refer to 73-00-00, REPAIR 012.
(4) Clean fuel filter (2) (73-00-00, CLEANING).
(5) Inspect fuel filter (2) (73-00-00, INSPECTION).
B. Install pressure test hardware as follows:
(1) Install pressure test fitting adapter LMT-805 (2, Figure 508) into fuel
injector inlet fitting. Tighten adapter (2).
(2) Install packing M83248/1-004 into packing groove on pressure test fitting LMT-
767 (1). Install test fitting (1) into fitting adapter (2). Tighten test
fitting (1).
(3) Install fuel injector test plug retainer assembly LMT-803 (4) as follows:
GE PROPRIETARY INFORMATION - Not to be used, disclosed to others or
Date Printed: reproduced without the express written consent of GE. Technical data is Page
Sep 8, 2009 considered ITAR and/or EAR controlled; transfer of this data to a Non-US 4 of 19
Person, without USG authorization, is strictly prohibited.
CT7-TP 9 MAINTENANCE MANUAL Revision No. 51 Dated 10/31/2002
MM 73-00-00
FUEL SYSTEM - TEST
Page Block Effectivity: * * * FOR ALL CT7-9 MODELS

NOTE: When installing packing retainer (3) into fuel injector, be sure that the
end with the 0.125 (3.18 mm) diameter hole is facing away from the fuel
injector.
(a) Install packing M83248/1-009 into packing groove on packing retainer.
Install packing retainer (3) (hole end facing away from fuel injector) into
fuel injector as shown on Figure 508.
(b) Unscrew thumbscrew (5) enough to allow installation of retainer assembly
(4) onto fuel injector.
(c) Install retainer assembly (4) onto the fuel injector by sliding the tangs
into the packing groove as shown on Figure 508.
(d) Turn thumbscrew (5) in a clockwise direction so that the point on
thumbscrew engages the hole on the end of packing retainer (3). Hand-
tighten the thumbscrew enough to hold retainer assembly (4) firmly in
place.
(4) Install clamp assembly LMT-804 (7) onto fuel injector tip as follows:
(a) Install packing M83248/1-003 into the packing groove located on the tip of
clamp screw (6). Unscrew clamp screw (6) enough to allow installation of
clamp assembly (7) onto fuel injector tip.
CAUTION: TIGHTEN CLAMP SCREW (6) ONLY ENOUGH TO HOLD CLAMP ASSEMBLY (7) FIRMLY IN
PLACE; OTHERWISE, DAMAGE TO THE FUEL INJECTOR CONE WILL OCCUR.
(b) Install clamp assembly (7) onto fuel injector tip. Hand tighten the clamp
screw (6) enough to hold clamp assembly firmly in place.
C. Pressure-test the fuel injector as follows:
WARNING: HIGH-PRESSURE TESTING
• HIGH PRESSURES USED DURING TESTING MAY CAUSE RUPTURING OR BURSTING OF FAULTY
TUBES AND HOSES. THE RESULT COULD BE SERIOUS INJURY.
• TO PREVENT INJURY, COVER ALL TUBES AND HOSES WITH A SUITABLE SAFETY SHIELD
DURING TESTING.
• WHEN CAPS OR PLUGS ARE USED, BE SURE THEY ARE SECURELY INSTALLED TO PREVENT
THEM FROM BEING BLOWN OUT.
• BE SURE THAT PRESSURES ARE BLED OFF BEFORE EXPOSING OR TOUCHING HOSES OR
TUBES.
(1) Attach high-pressure hose to pressure test fitting LMT-767 (1, Figure 508) and
tighten (30° wrench arc).
(2) Pre-set regulator on nitrogen bottle to 750 psig (5171 kPa).
WARNING: CALIBRATING FLUID
MIL-C-7024
• COMBUSTIBLE - DO NOT USE NEAR OPEN FLAMES, NEAR WELDING AREAS, OR ON HOT
SURFACES.
• PROLONGED CONTACT WITH SKIN MAY CAUSE IRRITATION. PROLONGED INHALATION OF
VAPOR CAN CAUSE DIZZINESS, HEADACHE, AND INTOXICATION.
• IF THERE IS ANY PROLONGED CONTACT WITH SKIN, WASH AFFECTED AREA WITH SOAP
AND WATER. IF LIQUID CONTACTS EYES, FLUSH EYES THOROUGHLY WITH WATER. REMOVE
SOLVENT-SATURATED CLOTHING. IF VAPORS CAUSE LIGHT-HEADEDNESS, GO TO FRESH
AIR. IF LIQUID IS SWALLOWED, DO NOT TRY TO VOMIT. GET MEDICAL ATTENTION.
• WHEN HEATED, HOT FLUID MAY CAUSE BURNS. AVOID CONTACT WITH HOT FLUID. IF
SKIN CONTACTS HOT FLUID, FLUSH AFFECTED AREA WITH COLD WATER FOR 10 MINUTES.
SEEK MEDICAL HELP IMMEDIATELY.

GE PROPRIETARY INFORMATION - Not to be used, disclosed to others or


Date Printed: reproduced without the express written consent of GE. Technical data is Page
Sep 8, 2009 considered ITAR and/or EAR controlled; transfer of this data to a Non-US 5 of 19
Person, without USG authorization, is strictly prohibited.
CT7-TP 9 MAINTENANCE MANUAL Revision No. 51 Dated 10/31/2002
MM 73-00-00
FUEL SYSTEM - TEST
Page Block Effectivity: * * * FOR ALL CT7-9 MODELS

• WHEN HANDLING OR WHEN APPLYING LIQUID AT AN AIR-EXHAUSTED WORKBENCH, WEAR


APPROVED GLOVES AND GOGGLES (OR FACE SHIELD).
• WHEN HANDLING OR WHEN APPLYING LIQUID AT AN UNEXHAUSTED WORKBENCH, WEAR
APPROVED GLOVES, GOGGLES (OR FACE SHIELD) AND APPROVED RESPIRATOR.
• DISPOSE OF LIQUID-SOAKED RAGS IN APPROVED METAL CONTAINER.
(3) Immerse the fuel injector into a container filled with calibrating fluid.
(4) Slowly open regulator valve and pressurize the fuel injector to 750 psig (5171
kPa). Allow fuel injector to remain immersed for a minimum of one minute.
(5) If no leakage is observed around the tubing or brazed joints the fuel injector
is acceptable. If leakage is observed check to be sure that leakage is not from
the test hardware; otherwise, scrap the fuel injector.
(6) Remove test hardware from fuel injector.
(7) Inspect packing groove (8, Figure 508) after removing the fuel injector test
plug retainer for nicks or scratches.
(8) Install new or previously removed (cleaned and inspected) fuel filter (2,
Figure 507) and new spring retainer (1) as follows:
CAUTION: • DO NOT POKE AT TIP OF THE FUEL INJECTOR (Figure 507). THIS CAN DAMAGE
THE FUEL INJECTOR AND COULD CAUSE EXCESSIVE FUEL FLOW FROM THE FUEL
INJECTOR AND SEVERE ENGINE DISTRESS DURING ENGINE OPERATION.
• DO NOT DAMAGE THE INSIDE DIAMETER OF THE FUEL INJECTOR DURING THE
INSTALLATION OF THE SPRING RETAINER.
• DO NOT USE NEEDLE NOSE PLIERS TO REMOVE THE SPRING RETAINER. DAMAGE TO
THE FUEL PASSAGE OF THE FUEL INJECTOR CAN OCCUR.
(a) Install the filter (2) into the fuel injector.
(b) Using the slotted and drilled end of the LMT-964 (Figure 507) tool, put the
stem of a new spring retainer (1) in the drilled hole of the LMT-964 and
engage the stem in the slot.
(c) Install the spring retainer (1) into the inside diameter of the fuel
injector as follows:
1 Tip the spring retainer removal/installation tool LMT-964 to the side.
2 Put the stem end of the spring retainer (1) into the hole in the tool.
3 Wind the spring retainer into the hole clockwise.
4 Push the spring retainer into the retaining groove.
5 Remove the tool from the spring retainer.
6. Testing Fuel Injector Flow Rate.
NOTE: • Fuel injectors can be flow-checked using calibrating fluid (step A), JP-5 fuel or
JET A fuel (step B), or compressed air (step C).
• Steps A and B are preferred to step C.
• The procedure in step C is not recommended for new operators.
A. Using calibrating fluid, flow-check fuel injectors as follows:
WARNING: CALIBRATING FLUID
MIL-C-7024
• COMBUSTIBLE - DO NOT USE NEAR OPEN FLAMES, NEAR WELDING AREAS, OR ON HOT
SURFACES.
• PROLONGED CONTACT WITH SKIN MAY CAUSE IRRITATION. PROLONGED INHALATION OF

GE PROPRIETARY INFORMATION - Not to be used, disclosed to others or


Date Printed: reproduced without the express written consent of GE. Technical data is Page
Sep 8, 2009 considered ITAR and/or EAR controlled; transfer of this data to a Non-US 6 of 19
Person, without USG authorization, is strictly prohibited.
CT7-TP 9 MAINTENANCE MANUAL Revision No. 51 Dated 10/31/2002
MM 73-00-00
FUEL SYSTEM - TEST
Page Block Effectivity: * * * FOR ALL CT7-9 MODELS

VAPOR CAN CAUSE DIZZINESS, HEADACHE, AND INTOXICATION.


• IF THERE IS ANY PROLONGED CONTACT WITH SKIN, WASH AFFECTED AREA WITH SOAP
AND WATER. IF LIQUID CONTACTS EYES, FLUSH EYES THOROUGHLY WITH WATER. REMOVE
SOLVENT-SATURATED CLOTHING. IF VAPORS CAUSE LIGHT-HEADEDNESS, GO TO FRESH
AIR. IF LIQUID IS SWALLOWED, DO NOT TRY TO VOMIT. GET MEDICAL ATTENTION.
• WHEN HEATED, HOT FLUID MAY CAUSE BURNS. AVOID CONTACT WITH HOT FLUID. IF
SKIN CONTACTS HOT FLUID, FLUSH AFFECTED AREA WITH COLD WATER FOR 10 MINUTES.
SEEK MEDICAL HELP IMMEDIATELY.
• WHEN HANDLING OR WHEN APPLYING LIQUID AT AN AIR-EXHAUSTED WORKBENCH, WEAR
APPROVED GLOVES AND GOGGLES (OR FACE SHIELD).
• WHEN HANDLING OR WHEN APPLYING LIQUID AT AN UNEXHAUSTED WORKBENCH, WEAR
APPROVED GLOVES, GOGGLES (OR FACE SHIELD) AND APPROVED RESPIRATOR.
• DISPOSE OF LIQUID-SOAKED RAGS IN APPROVED METAL CONTAINER.
CAUTION: WHEN FLOW-TESTING FUEL INJECTORS, TIP OF FUEL INJECTOR MUST NOT BE POINTING
DOWNWARD OR UPWARD; OTHERWISE, FLOW RATE WILL NOT BE ACCURATE.
(1) Supply calibrating fluid to fuel injector using the following limits:
• Temperature of fluid: 79°-82°F (26°-28°C)
• Pressure on flow test stand: 95-105 psig (655-724 kPa).
(2) The fuel injector flow must be within these limits:
* * * FUEL INJECTORS PN 5051T35G06 AND PN 5051T35G07
• For new fuel injectors: 54.0-58.0 lb/hr (24.5-26.3 Kg/hr)
• For used fuel injectors: 53.0-59.0 lb/hr (24.0-26.7 Kg/hr).
* * * FUEL INJECTORS PN 5051T35G01/G05 AND PN 5066T92G01/G02/G03/G07
• For new fuel injectors: 44.4-47.6 lb/hr (20.1-21.6 Kg/hr)
• For used fuel injectors: 43.5-48.5 lb/hr (19.7-22.0 Kg/hr).
* * * FOR ALL FUEL INJECTORS
(3) The spray pattern (Figure 509) of fuel injectors, without applying shroud air,
is acceptable if pattern is uniform, even if spray pattern contains streaks,
dribbles, or droplets. The spray pattern is not acceptable if spray pattern
contains voids or if pattern is asymmetric (not a symmetrical cone shape).
(4) If spray pattern of fuel injectors is asymmetric, or there are voids in spray
pattern without applying shroud air, do the following:
(a) Using fuel injector tip shroud air adapter, LMT-912, apply a maximum of 0.5
psig (3.5 kPa) shroud air and flow-check fuel injectors.
(b) Fuel injector is acceptable only if there is a uniform spray pattern.
(5) If flow limits are not within limits or if spray pattern is not acceptable,
clean injectors (73-00-00, CLEANING) and flow-check again. If still out-of-
limits after cleaning, replace injector.
B. Using JP-5 fuel or JET A fuel, flow-check fuel injectors as follows:
WARNING: AVIATION TURBINE FUEL (JET FUEL)
• FLAMMABLE - DO NOT USE NEAR OPEN FLAMES, NEAR WELDING AREAS, OR ON HOT
SURFACES.
• DO NOT SMOKE WHEN USING IT, AND DO NOT USE IT WHERE OTHERS ARE SMOKING.
• CONTACT OF SKIN WITH LIQUID CAN IRRITATE SKIN. CONTACT OF EYES WITH LIQUID
CAN CAUSE SEVERE IRRITATION AND BLURRED VISION. INHALATION OF VAPOR CAN
CAUSE IRRITATION, HEADACHE, NAUSEA, AND DIZZINESS.

GE PROPRIETARY INFORMATION - Not to be used, disclosed to others or


Date Printed: reproduced without the express written consent of GE. Technical data is Page
Sep 8, 2009 considered ITAR and/or EAR controlled; transfer of this data to a Non-US 7 of 19
Person, without USG authorization, is strictly prohibited.
CT7-TP 9 MAINTENANCE MANUAL Revision No. 51 Dated 10/31/2002
MM 73-00-00
FUEL SYSTEM - TEST
Page Block Effectivity: * * * FOR ALL CT7-9 MODELS

• IF LIQUID CONTACTS EYES, FLUSH THEM THOROUGHLY WITH WATER. IMMEDIATELY


REMOVE FUEL-SATURATED CLOTHING. IF VAPORS CAUSE DIZZINESS, GO TO FRESH AIR.
IF LIQUID IS SWALLOWED, DO NOT TRY TO VOMIT; GET MEDICAL ATTENTION.
• WHEN HANDLING LARGE QUANTITIES OF LIQUID (MORE THAN ONE GALLON (3.8 LITERS))
AT AN UNEXHAUSTED WORKBENCH, WEAR APPROVED RESPIRATOR AND GOGGLES OR FACE
SHIELD.
• DISPOSE OF LIQUID-SOAKED RAGS IN APPROVED METAL CONTAINER.
• METAL CONTAINERS OF FUEL MUST BE GROUNDED TO MAINTAIN ELECTRICAL CONTINUITY.
CAUTION: WHEN FLOW-TESTING FUEL INJECTORS, TIP OF FUEL INJECTOR MUST NOT BE POINTING
DOWNWARD OR UPWARD; OTHERWISE, FLOW RATE WILL NOT BE ACCURATE.
(1) Supply JP-5 or JET A fuel to the fuel injector. These limits apply:
• Temperature of fuel: 66°-70°F (19°-21°C)
• Pressure on flow test stand: 95-105 psig (655-724 kPa).
(2) The fuel injector flow must be within these limits:
* * * FUEL INJECTORS PN 5051T35G06/G07
• For new fuel injectors: 51.6-55.4 lb/hr (23.4-25.1 Kg/hr)
• For used fuel injectors: 50.5-56.5 lb/hr (22.9-25.6 Kg/hr).
* * * FUEL INJECTORS PN 5051T35G01/G05 AND PN 5066T92G01/G02/G03/G07
• For new fuel injectors: 42.4-45.6 lb/hr (19.2-20.6 Kg/hr)
• For used fuel injectors: 41.5-46.5 lb/hr (18.8-21.1 Kg/hr).
* * * FOR ALL FUEL INJECTORS
(3) The spray pattern (Figure 509) of fuel injectors, without applying shroud air,
is acceptable if pattern is uniform, even if spray pattern contains streaks,
dribbles, or droplets. The spray pattern is not acceptable if spray pattern
contains voids or if pattern is asymmetric (not a symmetrical cone shape).
(4) If spray pattern of fuel injectors is asymmetric, or there are voids in spray
pattern without applying shroud air, do as follows:
(a) Using LMT-912, apply a maximum of 0.5 psig (3.5 kPa) shroud air and flow-
check fuel injectors.
(b) Fuel injector is acceptable only if there is a uniform spray pattern.
(5) If flow limits are not within limits or if spray pattern is not acceptable,
clean injectors (CLEANING) and flow-check again. If still out-of-limits after
cleaning, replace injector.
NOTE: The flow check is not recommended for new operators (new operators can choose to
send the fuel injectors to an approved overhaul facility for flow check).
C. Use dry, filtered, compressed air, to functionally flow-check the fuel injectors
as follows:
WARNING: COMPRESSED AIR
• WHEN USING COMPRESSED AIR FOR ANY COOLING, CLEANING, OR DRYING OPERATION, DO
NOT EXCEED 30 PSIG (207 kPa) AT THE NOZZLE.
• EYES CAN BE PERMANENTLY DAMAGED BY CONTACT WITH LIQUID OR LARGE PARTICLES
PROPELLED BY COMPRESSED AIR. INHALATION OF AIR-BLOWN PARTICLES OR SOLVENT
VAPOR CAN DAMAGE LUNGS.
• WHEN USING AIR FOR CLEANING AT AN AIR-EXHAUSTED WORKBENCH, WEAR APPROVED
GOGGLES OR FACE SHIELD.
• WHEN USING AIR FOR CLEANING AT AN UNEXHAUSTED WORKBENCH, WEAR APPROVED
RESPIRATOR AND GOGGLES.
GE PROPRIETARY INFORMATION - Not to be used, disclosed to others or
Date Printed: reproduced without the express written consent of GE. Technical data is Page
Sep 8, 2009 considered ITAR and/or EAR controlled; transfer of this data to a Non-US 8 of 19
Person, without USG authorization, is strictly prohibited.
CT7-TP 9 MAINTENANCE MANUAL Revision No. 51 Dated 10/31/2002
MM 73-00-00
FUEL SYSTEM - TEST
Page Block Effectivity: * * * FOR ALL CT7-9 MODELS

NOTE: • Be sure that all connections are tight to prevent air leaks.
• The smallest ID of tubing recommended for use is 1/4 inch (6.4 mm).
• Tubes must be kept to minimum length.
(1) Set up fuel injector (Figure 510) for flow check.
(2) With the inlet pressure set at 65.5-66.5 psig (452-459 kPa), record the
downstream pressure. Air pressure downstream limits are as follows:
* * * FUEL INJECTORS PN 5051T35G01/G05 AND 5066T92G01
• 37.0-41.5 psig (255-283 kPa)
* * * FUEL INJECTORS PN 5066T92G02/G03/G07
• 48.0-54.0 psig (331-372 kPa)
* * * FOR ALL FUEL INJECTORS
(3) If the flow limits are not within limits, clean the injectors (73-00-00,
CLEANING) and flow-check again. If still out-of-limits after cleaning, replace
the injector.
* * * FOR ALL CT7-9 MODELS

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MM 73-00-00
FUEL SYSTEM - TEST
Page Block Effectivity: * * * FOR ALL CT7-9 MODELS

Figure 501 Pressure Test Fitting LMT-767


* * * FOR ALL CT7-9 MODELS

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FUEL SYSTEM - TEST
Page Block Effectivity: * * * FOR ALL CT7-9 MODELS

Figure 502 Fuel Injector Test Plug Retainer Assembly LMT-803


* * * FOR ALL CT7-9 MODELS

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FUEL SYSTEM - TEST
Page Block Effectivity: * * * FOR ALL CT7-9 MODELS

Figure 503 Clamp Assembly LMT-804


* * * FOR ALL CT7-9 MODELS

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FUEL SYSTEM - TEST
Page Block Effectivity: * * * FOR ALL CT7-9 MODELS

Figure 504 Pressure Test Fitting Adapter LMT-805


* * * FOR ALL CT7-9 MODELS

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FUEL SYSTEM - TEST
Page Block Effectivity: * * * FOR ALL CT7-9 MODELS

Figure 505 Fuel Injector Tip Shroud Air Adapter LMT-912


* * * FOR ALL CT7-9 MODELS

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FUEL SYSTEM - TEST
Page Block Effectivity: * * * FOR ALL CT7-9 MODELS

Figure 506 Spring Retainer Removal/Installation Tool LMT-964


* * * FOR ALL CT7-9 MODELS

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FUEL SYSTEM - TEST
Page Block Effectivity: * * * FOR ALL CT7-9 MODELS

Figure 507 Fuel Filter and Spring Retainer - Removal


* * * FOR ALL CT7-9 MODELS

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Page Block Effectivity: * * * FOR ALL CT7-9 MODELS

Figure 508 Fuel Injector PN 5051T35 - Pressure Test - Setup


* * * FOR ALL CT7-9 MODELS

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Page Block Effectivity: * * * FOR ALL CT7-9 MODELS

Figure 509 Fuel Injector Tip - Spray Patterns


* * * FOR ALL CT7-9 MODELS

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FUEL SYSTEM - TEST
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Figure 510 Fuel Injector Flow Check - Setup (Typical) Using Compressed
Air

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