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A SERVICE PUBLICATION OF
LOCKHEED-GEORGIA COMPANY
Troubleshooting
A DIVISION OF
LOCKHEED AIRCRAFT CORPORATION the Hercules Fuel Quantity
Editor
Jay V. Roy
Associate Editor
James A. Loftin

Art Direction & Production

Phillip E. Evans
by HAROLD COOK, Senior Functional Test Engineer and
ELBERT FIELDS, Service Analyst

Vol. 1, NO. 3, July- September 1974

WE’RE GOING to look at, specifically, the fuel quantity indicating system installed
on C-130B and subsequent Hercules aircraft. But the general information is
CONTENTS applicable to all capacitance-type indicating systems, such as those on the C-130A
Hercules Fuel Quantity Indicating and the JetStar.
System
2 Troubleshooting Troubleshooting a fuel quantity indicating system requires strict adherence to all of
6 Tank Units Part Numbers and Capacitance the safety precautions concerning such matters as fueling and defueling, open fuel
10 Troubleshootmg Chart tanks and proper test equipment. As a supplement to these safety precautions, the
I5 Fuel Weight To Capacitance
following procedures are recommended for troubleshooting the Hercules fuel
16 Connectors quantity indicating system:

I8 Delayed Maintenance. Can Give You Do not use electrical equipment capable of producing more than 200 milliamperes in
a Blast fuel tank measurements. Use only the MD-2A (FSN/4920-509-1508) automatic
capacitance bridge and low-voltage megohmmeter (megger) or TF-20
20 How JetStars Keep Their COOL
(FSN/4920-962-3027) automatic capacitance bridge, low-voltage megger, and
StarTips precision capacitors for all capacitance and resistance measurements.
15 Two Different Hercules Engine Driven
Hydraulic Pumps
With system or test equipment power applied to the fuel quantity indicating system
23 How the 1867th FCS Licked a Turbine (tanks not drained and purged), do not make or break any electrical connections in,
Problem or close to, the fuel tanks. Any connections required for continuity checks should be
made with or TF-20 test equipment de-energized. Energize test equipment
only after all connections are completed to verify continuity. De-energize test
equipment prior to disconnecting.

CAUTION: Do not apply power to the aircraft while fuel tank is open.

COVER: A Lockheed Flight Test crew boards a Any equipment used in testing or measuring fuel quantity indicating system
Canadian Armed Forces Hercules for an early components should be grounded to the aircraft and/or static ground prior to
morning takeoff. applying power to the equipment. Ground connections should not be assumed, they
should be checked.
Published by Lockheed-Georgia Company, a Division of
Lockheed Aircraft Corporation. Information contained in
The Hercules fuel quantity indicating system is a single-point ground system. On
this issue is considered by Lockheed-Georgia Company to some aircraft the shield of the coaxial cable is grounded only through the indicator,
be accurate and authoritative; it should not be assumed, while on production aircraft LAC 4454 and subsequent and in-service aircraft
however, that this material has received approval from any
modified in accordance with Service Bulletin 82-308 or 382-144 the ground is
governmental agency or military service unless ii is
specifically noted. This publication is for planning and through the aircraft structure near the indicator. The system is not grounded in the
information purposes only, and it is not to be construed tank. Depending on configuration, the shield may be above ground when the
as authority for making changes an aircraft or equipment
or as superseding any established operational or
indicator is disconnected. In addition, the case of the MD-2A or TF-20 has the same
maintenance procedures or policies. The following marks ground potential as the shield. This means that when one of these testers is being
are registered and owned by Lockheed Aircraft used to check the system, either in the cockpit or at the tank boundary (the point at
Corporation: “ “, “Lockheed”, “Hercules”, and
"JetStar" Written permission must be obtained from
which the wiring enters the tank) and the ground wire for the MD-2A or TF-20 is not
Lockheed-Georgia Company before republishing any connected, any voltage on the case of the tester (internal short in MD-2A or TF-20,
material in thin periodical. Address all communications to voltage on stand contacting case of the test equipment,etc.) may be applied directly
Editor, Service News, Department 64-22, Zone 278,
Lockheed-Georgia Company, Marietta, Georgia 30063.
to the shield of the coaxial cable inside the tank. Always ground the MD-2A or
Copyright 1974 Lockheed Aircraft Corporation. TF-20 to the aircraft structure prior to applying power to the test equipment.

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Previous Page Table of Contents Next Page
 FIGURE 1

CONNECTION OF MD-2A

Check power source for proper voltage (specified in The most common causes, and tbeir remedies are:
handbook or on test equipment) before connecting test
equipment to power source. Center conductor of coaxial cable shorted to shield
anywhere in the system, or internally shorted tank unit.
Any equipment in contact with the MD-2A or TF-20,
such as the stand, should also be grounded to the aircraft Open the circuit breaker for the system being tested,
4 and/or static ground. disconnect the cockpit indicator, and connect the
calibration harness and MD-2A or TF-20 per Figure 1 or
Do not use ohmmeters with unknown current capabilities Figure 2.
for resistance checks on the fuel quantity indicating
system. Use only MD-2A or TF-20. CAUTION: Connect ground wire from MD-2A or TF-20
per Figure 1 or Figure 2 before connecting to
Do not use high-potential tester or megger. Use only power source.
MD-2A or TF-20.
NOTE: Only the MD-2A will be referred to in the
Operations such as soldering should not be performed following tests. See “How to Use the TF-20” appearing
around the fuel tanks before draining and purging has later if this tester is to be employed.
been accomplished.
Connect the MD-2A to 115V, 400 Hz power, and position
Static-producing clothing should not be worn when power switch to ON. Allow approximately five minutes
working around fueling and defueling operations. for warm-up.

TROUBLESHOOTING . Reports of malfunctions in Calibrate the megohmmeter with the Megohmmeter

the fuel quantity indicating system will usually be Range Selector in both CAL positions then position the
expressed in terms of indicator performance. Examples: Megohmmeter Range Selector to Xl.
indicator drives to below zero indicator shifts up scale
or down scale in error (1000 lb., 2000 lb., etc.) Using the Capacitance-Megohms Selector (MD-2A), check
indicator is inoperative . the resistance for the A TO CRD (coaxial cable center
conductor to GRD) position. The total system resistance
Although a troubleshooting chart is included, let’s look at should be within the limits of Table 1.
the more common malfunctions as an aid in using the
chart. If the resistance reading is not less than the value shown in
Table 1 (Approximate total sytem resistance before
MALFUNCTION: INDICATOR IS AGAINST THE STOP indicator accuracy is affected), the cause is neither the
BELOW ZERO WITH FUEL IN THE TANK center conductor shorted to the shield nor an internally

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FIGURE 2

CONNECTION OF TF-20

shorted tank unit. If the resistance reading indicates that The short can be isolated to a wire segment and/or probe
the center conductor is shorted (approximately zero by using the MD-2A (A TO GRD switch position) and
resistance) to the shield (ground), this is the cause of the disconnecting segments of probe wiring, beginning with
indicator malfunction. the probe which is farthest from the tank boundary
connector(s) until the fault is cleared or only one wire
Approx. resist- segment is left. (NOTE: Reconnect each segment as the
TABLE 1
ance before in test progresses.)
dicator error 5
MD-2A switch Minimum resistance (Single mal- If the short has not cleared, the trouble is in the wiring
position in Megohms 1 function only)
outside the tank. While monitoring with the MD-2A (A
Tank Unit TO GRD switch position), disconnect wire segments until
A T 0 B 60 25M the fault is cleared, or only one wire segment remains.
AT0 GRD 40 5M You now have the fault isolated to two connectors and
B TO GRD 20 1M one length of wire. The fault will probably be in one of
compensator2 the connectors, and disassembly and recheck is the only
A T 0 B 60 30M way to determine which one. Disassemble and remove
B TO G R D 2 0 1M shield cup on only one connector at a time. Check from
the remaining connector to determine if fault is cleared. If
‘ R e f . T.O.‘s 5L14-3-21-43 and 5L14-3-21-13
this one is not the connector with the short, you now
‘Interchange tank unit and-compensator leads (Figure 1) for
compensator circuit check. have an excellent chance to create one when you
reassemble. So, during reassembly, be sure that none of
the individual shield strands protrude into the shield cap,
where they can contact the center conductor; avoid
With the MD-2A still connected to the indicator excessive heating of the dielectric in the connector (this
connector and the power switch (MD-2A) to OFF, causes the dielectric to have an affinity for water); and
disconnect the connector(s) at the tank boundary for the remove any bits of solder or wire before installing the
tank system under test. Position MD-2A power switch to snap ring and strain relief. Repeat for the other connector
ON and repeat A TO GRD resistance check. if fault is not cleared.

If the short has cleared, the trouble is probably in the If neither connector is at fault, replace the wire segment.
tank. (Recheck at the tank before opening.) In this case, There have been instances where the center conductor has
drain and purge the tank per the recommended procedure migrated through the dielectric and contacted the shield
before trying to locate the fault. The short will most after exposure to excessively high temperatures (hot air
likely be in one of the individual probe-harness leaks). Crushing the coaxial cable could also cause the
coaxial-cable connectors, or the tank boundary connector. same fault. (Text continued on Page 8)

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 TANK ORIGINAL MOD I

Lockheed P/N Vendor P/N FSN Lockheed P/N Vendor P/N FSN

Bladder 1st Unit 695799-1 FG220A-97 6680-585-9354 695799-63 FG220A-194 6680-05 I-6693
(Auxiliary) 2nd Unit -3 -96 -9363 -65 -193 -6694
3rd Unit -5 4 5 -9352 -67 -192 -6691
Compensator -7 FG260A-6 -0827 -69 FG250A-42 -089-5300

Inboard 1st Unit 695799-9 FG220A-108 6680-585-9350 695799-71 FG220A-205 6680-051-6702

2nd Unit -11 -109 -0811 -73 -206 -6690
3rd Unit -13 -110 -0820 -75 -207 -6700
4th Unit -15 -111 -082 1 -77 -208 -6687
5th Unit -17 -112 -0822 -79 -209 -6686
6th Unit -19 -113 -0823 -81 -210 -6686
7th Unit -21 -114 -0824 -83 -211 -6684
8th Unit -23 -1 16 -9351 -85 -212 -6699
Compensator -25 FG205A-7 -0828 -87 FG250A-43 -089-529s

6 Outboard 1st Unit 695799-27 FG220A-98 6680-585-0825 69579989 FG220A-195 6680-051-6683

2nd Unit -29 -99 -0826 -91 -196 -8849
3rd Unit -31 -100 -0817 -93 -197 -6688
4th Unit -33 -101 -1038 -95 -198 -6692
5th Unit -35 -102 -0816 -97 -199 -6698
6th Unit -37 -103 -9349 -99 -200 -6697
7th Unit -39 -104 -0815 -101 -201 -6696
8th Unit -41 -105 -08 14 -103 -202 -6689
9th Unit -43 -106 -0813 -105 -203 -6695
10th Unit -45 -107 -0812 -107 -204 -6701
Compensator -47 FG250A-8 -0810 -109 FG250A-44 -089-5298

Lock heed 1st Unit Center 695799-49 FG220A-178 6680-899-8663 695799-l 1 1 FG220A-215 6680-056-9542
Pylon 2nd Unit Center -51 -179 8664 -113 -216 -9543
(External) Aft Section -53 -177 -8662 -115 -214 -9541
Fwd Section -55 -176 8661 -117 -213 -9540
Compensator -57 FG6B-1 -853-1233 -119 FG6B-2 -071-3968

American 1 st Unit Center None EA772-2856 6680-869-9811

Electric 2nd Unit Center None -2867 -9812
Pylon Aft Section None -2858 -9613
(External) Fwd Section None -2859 -9814
compensator None 6 1115.2860 -9810
1
Same as ORIGINAL except inner electrodes and compensators have a coating to resist the effects of contaminants in the fuel.

‘Same as MOD I except equipped with new connectors per MIL-C-255166 and internal wiring improvements. This configuration
installed as a part of TCTO 741, and is the preferred replacement.

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 MOD II
2 DRY CAPACITANCE IN MMF

Lockheed P/N Vendor P/N FSN Tank Unit Compensator

695799-l 21 FG220A-239 6680-968-3227 50.8-52.8

-123 -238 -3226 27.3-28.9
-125 -237 -3225 57.7-60.1
-127 FG25OA-51 -3277 30.2-31.8 29.5-31.1
Empty 169.8 (166.4-173.5) 30.3
Added 188.0 * 31.7
Full 357.8 Jic 62.0

695799-1 29 FG220A-250 6680-968-3260 27.0-28.6

-131 -251 -3261 3 1.2-32.8
-133 -252 -3263 33.0-34.6
-135 -253 -3266 32.1-33.7
-137 -254 -3269 33.6-35.2
-139 -255 -3270 31 .O-32.6
-141 -256 -327 1 26.4-28.0
-143 -257 -3273 28.2-29.8
-145 FG250A -52 -3278 6.7-8.3 29.5-31.1
Empty 256.4 (251.3-261.5) 30.3
Added 291.2* 31.7
Full 547.6 * 62.0

695799-147 FG220A-240 6680-968 -3228 10.2-I 1.8 7

-149 -241 -3229 18.2-19.8
-151 -242 -3230 24.7-26.3
-153 -243 -3242 19.7-21.3
-155 -244 -3243 14.7-16.3
-157 -245 -3247 13.2-14.8
-159 -246 -3251 13.7-15.3
-161 -247 -3252 26.7-28.3
-163 -248 -3255 3 1.6-33.2
-165 -249 -3258 27.2-28.8
-167 FG25OA-53 -328 1 5.0-6.6 29.5-31.1
Empty 213.7 (209.4-218.0) 30.3
Added 241.6 * 31.7
Full 455.3 * 62.0

695799-169 FG22OA-260 6680-968 -32 13 84.2-85.8

-171 -261 -3223 81.7-83.3
-173 -259 -3212 80.2-81.8
-175 -258 -3197 8 1.4-83.0 29.5-31 .I
-177 FG6B-3 -3224 Empty 3 3 0 .7 (324.1-337.3) 30.3
Added 391.2 * 31.7
Full 721.9 * 62.0

84.2-85.8
8 1.7-83.3
80.2-8 1.8
8 1.4-83.0 29.5-3 1.1
Empty 330.7 (324.1-337.3) 30.3
Added 391.2 * 31.7
2ND
9TH
Compensator 6TH I 7TH 5TH
8TH 4TH Full 721.9 * 62.0

FUEL TANK UNIT AND COMPENSATOR LOCATIONS * Increase value shown by 5% for tanks with foam installed.

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 Open coaxial cable (center conductor) or unshielded tank
unit wire, outside or inside the tank.

With the MD-2A connected to the indicator harness

connector, check the capacitance of the tank units.

NOTE: Ground the compensator lead when checking the

tank units.

If the capacitance is approximately zero, the break is in,

or between, the tank boundary connector and the two
closest probes. This fault is generally the result of
pushed-back pin, cold solder, or broken wire in the probe
or harness connectors. This type fault may appear
intermittently as a result of altitude (temperature),
descent, flap operation, etc. Although not as common as
the above, the open circuit can occur in the probe wiring
in the head of the probe with the same results.

FRONT PANEL, MO-1 TESTER NOTE: When checking wiring in the tank, make sure that
all the wire harnesses have sufficient slack, the nuts on the
rear of the coaxial cable connections are tight, and the pin
is not pushed back in the dielectric.

If the capacitance reading is greater than the probe closest

to the tank boundary, add the values of the individual
FIGURE 3 probes in sequence from the tank boundary until the sum
lNDlCATOR
CONNECTOR is approximately equal to the capacitance reading. You
8 now have the break isolated to one length of wire and two
probes.

NOTE: See Table 2 for probe capacitance values.

Indicator improperly calibrated.

If the tank contains fuel, disconnect the indicator and

connect calibration harness and MD-l
(FSN/6625-302-4802) as shown in Figure 3. The MD-1
Tester supplies equivalent capacitance for testing and
CONNECTION OF MD-1 calibrating fuel quantity indicators. Adjust the C-3 section
(ALTERNATE CALIBRATION) of the MD-l to 62.0 MMF and the C-l section to the
nominal empty value of capacitance for the tank being
checked. (See Table 2).
FIGURE 4
NOTE: When calibrating or checking the indicator at
empty, the compensator may be either the dry or wet
value of capacitance without affecting the accuracy of the
indicator calibration.

Adjust the C-l section of the MD-1 to position the

indicator pointer to the empty graduation. The
capacitance should be within +4 percent of the nominal
empty capacitance.

Now, for the full check, adjust the C-l section of the
MD-l to the sum of the nominal empty capacitance, plus
CONNECTION OF MD-1 the added capacitance (full capacitance). Continue to
(PREFERRED CALIBRATION) adjust (if required) until the indicator pointer coincides

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with the full (last scale) graduation. The capacitance
should be within +4 percent of the full capacitance.

If the check demonstrates that the indicator is improperly

calibrated, it is preferable to drain the tank and calibrate
the indicator to a dry tank (preferred method Figure 4). If
time will not permit the preferred method of calibration,
the indicator can be calibrated for “empty”, using the
nominal empty capacitance, and for “full”, using the
nominal full capacitance (“empty” plus added
capacitance). When using this alternate method, you are
assuming the integrity of the tank wiring and probes.
Some degree of confidence in this method of calibration
can be had by using a dipstick if the aircraft is in a level
attitude (0 roll and 0 pitch). FRONT P A N E L , TF-20-1 T E S T E R

Front panel of TF-20-I t e s t e r (FSN/4920-962-3097) which is

NOTE: Do not calibrate the indicator to the dipstick. version of TF-20 in waterproof case with added Capacitance

Your calibration will be much more accurate if the Simulator CV-86-1 mounted on right side of panel. The extra
capacitance simulator is independent of the TF-20 portion and is
dipstick is used only to show that the calibration is
included for specific applications such as the KC/LC-130F fuselage
approximately correct. gauge system.

Agreement between the dipstick and indicator within 500

to 600 pounds (especially if the aircraft is not perfectly FUEL RESISTANT UNSHIELDED LEAD WIRE

level) is generally an indication that the empty INSULATION

TEFLON (TFE)
capacitance limits (100 to 200 pounds) is the only added
error.

MALFUNCTION: INDICATOR AGAINST THE STOP

9
ABOVE THE LAST SCALE GRADUATION

The most common causes, and their remedies, are:

Open circuit in shield between individual indicator and

tank boundary connector.

COPPER BRAID CENTER CONDUCTOR

With the MD-2A connected per Figure 5, disconnect the FUEL RESISTANT COAXIAL (SHIELDED) CABLE
connector(s) at the tank boundary. With MD-2A
Megohmmeter Range Selector at Xl, position the
TF-20 ADAPTER CABLES FOR TESTING TANK UNITS
Capacitance-Megohms Selector to A TO GRD. AND COMPENSATORS OUT OF TANK OR AT TANK
BOUNDARY OF AIRCRAFT MODIFIED PER TCTO 1C-130-741
Megohmmeter should read infinite resistance (full CCW).
VENDOR P/N
Connect a jumper from the coaxial cable center conductor 1211.404 UG 88/U

to the shield at the tank boundary connector and observe COAX

megohmmeter for continuity ( no change: open shield-
full CW: continuity).
AG 103A 4.
AMPHENOL 14625,
VENDOR P/N HONEYWELL 412270C. 412266R
If open, isolate to a connector and repair as necessary. 1231-106 OR EQUIVALENT

UNSH
Open circuit in shield between individual probes within
the tank.

VENDOR P/N

If continuity exists with the MD-2A connected and 1231 206 UG 88/U

operated as described above, the open circuit is in the

tank. With the tank drained and purged and the MD-2A WRAP CABLE WITH TAPE TO BUILD UP SIZE SO
connected per Figure 5, use the megohmmeter section of CONNECTORS ON TF-20 THAT CONNECTOR WILL CLAMP SECURELY,
ARE BNC TYPE. COAX SHIELD MUST MAKE POSITIVE CONTACT
the MD-2A to isolate open shield. (Text continued on Page 12) WITH UG-88/U SHELL.

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 MALFUNCTION SYMPTOM
FIG URE 5
Indicator against stop below zero with
fuel in the tank

I
I
I
I COMPENSATOR

CONNECTION OF MD-2A AT TANK BOUNDARY

(CAPACITANCE CHECK)

Intermittent counterclockwise
FIGURE 6 rotation of indicator
VENDOR P/N’s REAR
OPTIONAL CAPACITANCE TEST HARNESS
TO FACILITATE USE Of MD-2A (FUNCTIONALLY SAME AS
FIGURE 5) OR TF-20. ALSO USE0 WITH MO-2A OR TF-20 TO
TEST PROBES ON THE BENCH.

HONEYWELL 41227OC. 412266R, TERMlNAL STRIP

3 MAKE FROM VEN OOR P/N
AG 103A-4, 165-61 (*)-1014
I I I REAR BEAM Indicator shifts downscale in error or
AMPHENOL 14625, OR 165-61(*)-1011
OR EQUIVALENT. DPDT 1
TOGGLE SWITCH drives to stop below zero when fuel
UNSH level is below a specific value
UNSH
\ c
BOX-
T.U. COMP
- - -
COAX
COAX COAX

3
UG-88/U
10
SMALL METAL
BOX OR CAN Indicator against stop above full

UNSH H
COMP REAR BEAM
l

. UNSH COMP
0

COAX COAX

TANK INDICATOR
UNIT INDICATOR
HARNESS Indicator shift upscale in error or
drives to stop above full when fuel
DETAIL A DETAIL B level is above approximately one-half
tank
REMOVE CLOCKING
(DARK AREA)
Intermittent clockwise rotation of
indicator

REMOVE LOCKING PINS (DARK AREA)

BY DRILLING (l/8 DIA.) HOLE (2 PLACES) TRIM CONNECTOR SHELL (END WITH
IN NUT. POLARIZING KEYWAY LOCKING GROOVES)
TYP FOR ALL VENOOR P/N 165-61(*)
SERIES CONNECTORS

5/16
Totalizer indicator reads incorrectly
continuously or fluctuates between
1 BEFORE TCTO 1C-130-741
two fuel quantities
AFTER TCTO 1C-130-741

3 / 4 ” DIA. END 5 / 3 2 SLOT

3 REMOVE POLARIZING
THREADS TO MATE TRIMMED PORTION OF
TAB & DRILL OUT LOCKING
VENDOR P/N 165-67(*)
PINS PER DETAIL A.
MADE FROM STAINLESS STEEL TO PROTECT
CONNECTOR PINS AFTER SHELL IS TRIMMED.
4 REMOVE POLARIZING Indicator drifts slowly upscale or
RING OR ALTER PER ALTERATION TO VENDOR P/N 165-67(*)
SERIES CONNECTOR
downscale ( usually upscale).
DETAIL B.

(*) SINCE CONNECTOR IS TO BE DEPOLARIZED, YOU MAY USE A CONNECTOR OF ANY POLARIZATION LETTER. Interaction (more than one indicator
moving) between indicators when
only one test button is pressed.

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CAUSE REMEDY

Compensator in water Remove water from tank.

NOTE: Water causes capacitance of compensator to be extremely
high, thereby causing indicator to go d o w n s c a l e

Open circuit in either unshielded or coaxial lead between indi- Check continuity of unshielded and coaxial leads.
vidual tank indicator and rear beam harnessconnector

Open circuit in either unshielded or coaxial lead between indi- Check continuity of unshielded and coaxial leads. Repair as necessary.
vidual probes within tank boundary NOTE: Open circuit can exist within coaxial connector inside
tank as described below.

Short between coaxial lead center conductor and shield Check continuity of coaxial center conductor (high lead) and shield.
(Short may exist within coaxial connectors.)

Indicator defective or improperly calibrated Recalibrate or replace indicator as required.

Intermittent open circuit in either unshielded or coaxial lead Check continuity of unshielded and coaxial lead. Repair as necessary.
between individual tank indicator and rear beam harness

Intermittent open circuit in either unshielded or coaxial lead Check continuity of unshielded and coaxial lead. Repair as necessary.
between individual probes within tank boundary NOTE: Open circuit can exist within coaxial connector inside
tank as described above.

Intermittent short between coaxial lead center conductor and Check continuity of coaxial center conductor (high lead) and shield.
shield (Short may exist within coaxial connectors.)

Compensator in water Remove water from tank.

Low resistance path between electrodes of compensator Replace compensator.

and/or probe

Open coaxial lead between probes within tank boundary or Isolate fault to a connector or probe and replace or repair as necessary.
open unshielded lead between individual probe and
connector within tank boundary

Open circuit in shield between individual tank indicator and Check continuity of shield. Repair as necessary.
rear beam coaxial connector

Open circuit in shield between individual probes within tank Check continuity of shield. Repair as necessary.
boundary

Defective indicator or improperly calibrated Recalibrate or replace indicator as required.

Probes in water. NOTE: Water causes capacitance of probes to Remove water from tank.
be extremely high, thereby causing indicator to go upscale.
“.
Open compensator wiring, either internal or external Repair wiring as necessary or replace compensator.
(_j
Intermittent discontinuity of shield components of coaxial Disassemble coaxial connector and verify shield connections. Check
connectors shield connections at all other terminating points.

Intermittent open circuit in shield between individual tank Check continuity of shield. Repair as necessary.
indicator and rear beam coaxial connector

Intermittent open circuit in shield between individual probes Check continuity of shield. Repair as necessary.
within tank boundary
”
Incorrectly calibrated Recalibrate totalizer.

Individual tank indicator malfunctioning Correct indicator malfunctions as described above and recheck totalizer.

Short or open in totalizer circuit Continuity check for malfunction and repair as necessary.

Malfunctioning totalizer indicator Replace indicator.

Ineffective indicator (Pin J) power and/or coax shield ground. Clean and/or tighten ground stud. (See Figure 7)
(Should be less than one milliohm)

Ineffective indicator (Pin J) power and/or coax shield ground. Clean and/or tighten ground stud. (See Figure 7)
(Should be less than one milliohm)

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 Position MD-2A selector to A TO GRD, with indicates the same as for ZERO CAL position.
Megohmmeter Range Selector to Xl. The meter should Disconnect COMP, COAX, and UNSH cables from
indicate full CCW. Now disconnect the coaxial cable TF-20. The indicator should read the same as for
connector at the probe closest to tank boundary, and ZERO CAL.
connect a jumper from the shield section of the connector
to the center conductor. Observe megohmmeter for NOTE: This checks the integrity of the TF-20 and
continuity (full CW). Continue in sequence, reconnecting associated cables.
each segment after testing, until continuity fails to exist
and you have located the open shield. Reconnect COMP,. COAX, UNSH cables to Tank
Unit Section of TF-20.
Probes in water or water contaminated probes.

With the MD-2A connected per Figure 1, check resistance

Now we are ready to check and/or calibrate a fuel
for Capacitance-Megohms Selector positions A TO B, A
quantity indicating system. Using the TF-20 harness
TO GRD, and B TO GRD. Interchange compensator and
shown in Figure 2 (the type normally furnished with the
tank cables and repeat checks. Resistance values for all
TF-20) let’s check and calibrate a typical system.
positions of the selector will be lower than the values
presented in Table 1, indicating that probes are in water or
Connect the TF-20 to a source of 1 15V, 4OOHz (no
are contaminated.
attention to polarity is required because of the isolation
transformer in the TF-20).
Position selector to CAP UUF and check capacitance of
probes and compensator. Capacitance will be extremely
Position TF-20 power switch to OFF and connect to
high, usually driving the Capacitance Indicator full CW,
indicator and aircraft harness per Figure 2.
even on the X50 position, if a probe is in water.
NOTE: When using Capacitance Indicator, set Range
HOW TO USE THE TF-20 . . . The TF-20 is an automatic
Selector to the lowest multiplier possible for greatest
capacitance bridge (like the MD-2A) and two variable
accuracy. Set Megohmmeter ‘Range Selector to the
capacitor circuits (like the MD-l) related in the same
multiplier that causes indicator to read nearest mid-scale.
12 manner as the compensator and the tank units of a fuel
quantity indicating system.
CAPACITANCE CHECK
Connect TF-20 per Figure 2, except leave the aircraft
harness connector disconnected, and proceed as follows:
Set Cap-Res Check to CAP.

Position Function Selector to ZERO CAL, Set Function Selector to TANK UNIT TEST-COMP and
Cap-Res Check Selector to CAP, and Range read capacitance of compensator. UNSH lead is grounded
Selector to Xl. internally.

Adjust the Zero Adj until the Capacitance Indicator Set Function Selector to TANK UNIT TEST-UNSH and
Pointer coincides with the zero graduation. read capacitance of tank units (probes). Compensator lead
is grounded internally.
Position Function Selector to HIGH CAL and set
Range Selector as required.
RESISTANCE CHECK
l Adjust High Adj until Capacitance Indicator
coincides with the value of capacitance stamped on Check megohmmeter at zero and mid-scale settings of
the plate below the Function Selector. Range Selector; adjust if required.

Repeat these four steps until no further adjustment Cap-Res Check Function Selector Read Resistance
is required (just like a fuel gage calibration). Switch Position Position Between

NOTE: Do not adjust High Adj to position A-C, A-B TANK UNIT TEST-COMP COAX and COMP
indicator to last scale division. Adjust only to the A-C, A-0 TANK UNIT TEST-UNSH COAX and UNSH
value on the plate. A-GRD TAN K UN IT TEST-UNSH COAX and GRD
or COMP
Position the Function Selector to TANK B-GRD, C-GRD, TANK UN IT TEST-COMP COMP and GRD
UNIT- COMP and verify that Capacitance Indicator B-GRD, C-GRD TANK UNIT TEST-UNSH UNSH and GRD

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FIGURE 7
r

TANK NO. 1

11 J INDICATOR
E (TYPICAL)
B
I
F
I C

FUEL SYSTEM CONTROL PANEL

GROUND STUDS

CALIBRATION
Set Cap-Res Check to CAP and Function Selector to Now adjust controls per above to position Capacitance 13
COMP SET. Indicator to dry capacitance value of probes obtained
during capacitance check.
NOTE: The fuel quantity indicator will drive to the stop
below zero while Function Selector is in either COMP Position Function Selector to TEST.
SET or PROBE SET. The TF-20 Capacitance Indicator
only is connected to the capacitors when Function NOTE: This switches the values of capacitance set in
Selector is in either of the SET positions. COMP SET and PROBE SET from the TF-20 Capacitance
Indicator to the aircraft indicator. The TF-20 pointer will
Now add the value of the dry compensator (reading drive to zero.
obtained during capacitance check) to the added
capacitance value for the compensator. Adjust fuel quantity indicator to position the pointer at
zero.
A wet compensator during empty calibration does not
change the calibration accuracy. In other words, you can Position Function Selector back to PROBE SET.
use the dry or wet value for empty calibration; but a wet NOTE: The fuel quantity indicator will now drive to the
compensator value must be used for full calibration. stop below zero.

Adjust Comp Capacitance Control to position the Add the added capacitance value to the dry probe value.
Capacitance Indicator to the wet compensator value (dry This will be the full calibration value.
reading plus added capacitance).
Set Probe MMF Fixed Selector and Variable Probe MMF
Position Function Selector to PROBE SET. control to position the TF-20 Capacitance Indicator to
this value. Position Function Selector to TEST.
Set Probe MMF Fixed Capacitor Selectors to a
capacitance value as near desired capacitance as possible, Adjust fuel quantity indicator until the pointer coincides
but not exceeding this value. with the last scale graduation.

Make trimming adjustment to obtain exact value with Repeat empty and full calibration until no further
Probe Variable Control. adjustment is required.

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 NOTE: Remember, when the TF-20 Capacitance An open shield always causes high capacitance readings
Indicator is reading capacitance, the aircraft fuel quantity for both the compensator and the tank units (probes).
indicator capacitance leads are open.
A water-contaminated probe and compensator can
INDEPENDENT USE. . . Each section of the TF-20 can either a positive or negative error in the indicator.
be used independently of the other section. If MD-2A
capability only is required, connect the coaxial cable to Contaminated probes can generally be restored by
the TANK UNIT section COAX connector, and carefully washing in water and a mild detergent, thorougly
unshielded lead to either COMP or UNSH connector. rinsing in clear warm water, and baking dry. Drying
Function Selector must be positioned to coincide with temperature should be approximately 150°F, a s
connections (TANK UNIT TEST-COMP or PROBE). mentioned above, and shop air must not be used to blow
moisture out of probes, since it can recontaminate the
If MD-1 capability only is required, use the TEST IND probe with oil mist and dirty water.
connections.
Intermittent malfunctions that will not repeat on the
TO CHECK A PROBE FOR CONTAMINATION.. ground can usually be located by monitoring the
After completion of the dry capacitance check of the capacitance of the tank units with the MD-2A or TF-20,
individual tank unit or tank unit and compensator, as while lightly pulling and flexing the wiring and connectors
d e t a i l e d i n T.O.'s 5L14-3-21-13 a n d 5L14-3-21-43, in the tank. Any change in the capacitance reading is
immerse the end of the tank unit or tank unit and cause to disassemble and inspect a suspect connector.
compensator in approximately six inches of clear tap Capacitance decrease indicates an open coaxial cable
water (with the probe still connected to MD-2A or center conductor, an open unshielded lead, or the coaxial
TF-20). The capacitance will increase and the bridge cable center conductor shorted to its shield. Capacitance
(MD-2A or TF-20) will not balance if the probe is allowed increase indicates open coaxial shield.
to remain in the water.
Excessive moisture in the coaxial cable connectors can
Remove the probe from the water and thoroughly shake cause the indicator to read in error.
off the residual water.
14 If you calibrate an indicator by the preferred method
(added capacitance to a dry tank) with the compensator
Continue to monitor capacitance with an MD-2A or partially immersed in fuel, the indicator will have a
TF-20. If the unit is not contaminated, the capacitance positive error. EXPLANATION: Added capacitance plus
should, within 20 seconds after removal of the residual dry compensator equals a wet compensator. Added
water, return to within +2 MMF of the value noted during capacitance plus a partially wet compensator equals
the dry capacitance check before water immersion. The abnormally high compensator capacitance. When MD-l is
length of time required for the probe to return to its removed and aircraft wiring reconnected, the compensator
normal capacitance is proportional to, and an indication capacitance presented to the indicator is now lower in
of, the extent of contamination. value, and the indicator will move upscale in error, except
at empty. Monitor the compensator capacitance with the
Failure to pass this test is not justification to discard the MD-2A or TF-20 just prior to calibration to determine
probe. It does indicate, however, that the probe should be that residual fuel has not drained back on the
washed, as described later under the quick reference compensator.
troubleshooting tips.
Sluggish, slow moving indicators can be caused by
Repeat these tests. If the probe passes, it should be ready contaminated probes and compensators (low resistance
for further service. paths between the electrodes), moisture in connectors,
and shorts in system wiring.

You can check the coaxial cable from the cockpit to the
For Quick Reference, here are a few Hercules fuel tank boundary for stray capacitance by simply
quantity indicating system troubleshooting tips.... disconnecting the connector(s) at the tank boundary and
reading capacitance on the MD-2A or TF-20 in the
cockpit. Capacitance should be nearly zero.
A positive error in the compensator causes a negative error
in the indicator reading. Intermittent faults in test cables can cause you to draw
conclusions that are misleading, resulting in
A negative error in the compensator causes a positive error time-consuming unnecessary replacement of serviceable
in the indicator reading. components.

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The compensator is the greatest offender with respect to
water contamination. TWO DIFFERENT HERCULES ENGINE
DRIVEN HYDRAULIC PUMPS
Two manufacturers are now supplying engine
Hercules Fuel Quantity Indicator Linearity
driven hydraulic pumps for our Hercules air-
Except C-130A & D Series
Major Dial (Fuel Weight to Capacitance)
planes. Most of the commercial and foreign
Calibration Capacitance military configurations are equipped with pumps
In Pounds In mmf * manufactured by Vickers Aerospace Division,
Outboard Tank Indicators Sperry Rand Corporation. U.S. Military config-
0
2.57mmf/100 Ibs
213.5
urations have the pump manufactured by New
1000 239.2 +/-5 York Air Brake Company installed as original
2000 264.9 +/- 5 equipment. For resupply purposes the U.S.
3000 290.6 +/- 5 Military has procured some Vickers pumps and
4000 316.3+/- 5 we understand these are being installed on
5000 342.0 +/-5 C-130A models only.
6000 367.7 +/- 5
7000 393.4 +/- 5 The StarTips item on “How to Bleed a Hercules
8000 419.1 +/- 5
Hydraulic Pump - and Keep it Clean” in our
9000 444.8 +/- 5
9400 455.1 April - June 1974 issue Service News applies
only to the New York Air Brake pump
Inboard Tank Indicators installation. Fluid under pressure from the
3.31 mmf/100 Ibs suction boost pump can pass through the NYAB
0 256.4
1000 289.5 +/- 7 pump by opening the check valves at the ends of
2000 322.6 7 the cylinders, although this engine driven pump is
3000 355.7 +/- 7 not rotating. This installation includes a “run
4000 388.8 +/- 7
around” loop of tubing (C-130B model and up)
5000 421.8 +/-7
6000 454.9 +/-7 to cool and recirculate fluid to prevent the pump
7000 488.0+/- 7 from overheating when the pump is in “isola-
8000 521.1 +/-7 tion”; i.e., pump switched off with engine
8800 547.6 turning. Part numbers for these NYAB pumps are
15
66WBD300, 66WBD300-1, 66WBD300-4 a n d
Auxiliary Tank Indicators
2.85mmf/100 Ibs 66W U300-2.
0 169.8
1000 198.3 +/- 6 The newer Vickers part number
pump,
2000 226.8 +/- 6
PV3-075-4, does not require the external loop for
3000 255.3 +/- 6
4000 283.7 +/- 6
cooling. Also, the Vickers pump must rotate for
5000 312.2+/-6 fluid to flow through it. In both installations,
6000 340.1 +/- 6 rotation of the engine rotates the pump.
6600 357.8
The suction boost pumps located near the
Pylon (External) Tank Indicators reservoirs are used to provide a positive hydraulic
3.99mmf/100 Ibs
0 330.7 pressure of 70-l 10 PSI to the suction side of each
1000 370.6 +/- 8 engine driven pump when turned on. This
2000 410.5+/-8 pressure prevents cavitation and helps to “prime”
3000 450.5 +/- 8
4000
an engine driven pump should air get into the
490.4 +/- 8
5000 530.3 +/- 8 suction line. If the reservoir fluid level is kept
6000 570.2 +/- 8 within limits and correct maintenance procedures
7000 610.1 +/- 8 are followed, air will not enter the system.
8000 650.0+/- 8
9000 690.0 +/- 8 When a hydraulic component is replaced, the
9800 721.9 cavities of the new unit should be filled with
system fluid (MI L-H-5606) just before installation
* Increase value shown by 5% for tanks with foam installed.
to minimize entrapment of air. This is especially
true when replacing engine driven pumps, Always
Use this table to check the validity of any calibration you suspect
fill the pump case to overflowing through the case
may have been made using a dipstick. Chances are you will
decide to recalibrate using the preferred or alternate method. drain port. Also, retain as much fluid as possible
in disconnected tubing during component
changes. Become familiar with all the instruc-
tions in your maintenance manuals to avoid extra
expense - and work.

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 b y ELBERT FIELDS, Service Analyst

C o r r e c t assembly of the Cinch NuLine fuel quantity sure the groove in the V-gasket is pointing forward and the
indicating system connectors is very important. Assembly internal taper of the braid clamp collar conforms to the
instructions for coaxial (shielded) cable connectors (NuLine brushed-back braid on the braid clamp. Assembly of the
Part Numbers 12 1 l-404 and 122 l-404) are shown in Figure 2 connector with the internal taper of the braid clamp collar
and instructions for unshielded lead connectors (NuLine Part backwards will shear the shield braid, resulting in an
Numbers 1231-106, 1231-206, 1244-106, 1244-206, intermittent connection.
1246-106 and 1246-206) are shown in Figure 3. It is
important to torque correctly the hex back-end nut to insure
that the V-gasket is cut, providing metal-to-metal locking of On the rear wing beam, at the outer wing break and at the
the shielding to the shell, maximum environmental pylon tank disconnect, three new connectors replace one
protection (moisture sealing), and effective locking of the earlier multipin connector, bringing each lead through a
back-end nut. The .042 inch maximum gap between the nut separate connector. A new adapter fits the existing multipin
and body assembly is a good indication the nut has been connector hole, and new holes are drilled for the remaining
properly torqued. connectors.

If for any reason a connector is disassembled, a new V-gasket Information regarding fuel quantity wire and cable used with
(also called a chevron washer) must be installed. (See the new connectors is detailed in an article, “Hercules Wire
Figure 1 for part number.) All pieces of the old V-gasket Identification”, Page 9 of the April - June 1974 issue of
must be removed. If the braid clamp collar is missing, check Service News.
16 inside the shell. Be sure the braid is not broken and is
smoothly combed in place before reassembly. Also, make Here is a table listing the NuLine connectors:

FIGURE 1 F U E L QUANTITY INDICATING SYSTEM CONNECTORS USED ON C-l 30 HERCULES AIRCRAFT

Item No. NuLine Federal Stock No. Description Type Contact V-Gasket Front Gasket Replaces
P/N P/N* P/N* P/N*

P-870 1211-404 5935-071-7329 Shielded Cable Pin B 138009 A 138007 5329-1

Plug
J-502 122 I-404 5935-071-7330 Shielded Cable Socket B 138009 None 5166-I
Jack
P-67 1 1231-106 5935-909.2358 Unshielded Cable Socket B 138014 A 138006 1-906-l
Plug
P.872 1231-206 5935-946-Q 1 94 Unshielded Cable Pin B 138014 A 138007 1-728-1
Plug
J-514 1244-l 06 5935-071-7331 Glass Seal Bulkhead Pin B 138014 None
Feed Thru Unshielded
Combinations
Cable Jack
of these
J-512 1244-206 5935-07 1-7332 Glass Seal Bulkhead Socket B 138014 None
connectors
Feed Thru Unshielded
replace Vendor
Cable Jack
P/N’s
J-517 1246-l 06 5935-07 I-7333 Bulkhead Feed Thru Pin B 138014 None
165-67,
Unshielded Cable Jack
165-67W, and
J-516 1246-206 5936-947-9275 Bulkhead Feed Thru Socket B 138014 None
165-67X
Unshielded Cable Jack
J-513 1284-451 NSL Isolated Ground Socket None None
Bulkhead Feed Thru I
Adapter
*Federal Stock Numbers have not been assigned to the gaskets.

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CONNECTORS
FIGURE 2
STEP 1. FLAT WASHER KNIFE EDGE
, _ B R A l D
SLIDE THE HEX NUT, FLAT WASHER AND V-GASKET OVER THE
JACKET. SCREW THE THREADED BRAID CLAMP OVER THE JACKET,
NOTE: TAKE CARE NOT TO DAMAGE KNIFE EDGE OF BRAID CLAMP.
STRIP THE JACKET UNTIL 12
/ INCH OF BRAID IS EXPOSED. SCREW THE BRAID CLAMP COLLAR
BRAID CLAMP BACK UNTIL IT IS FLUSH WITH EDGE OF JACKET. NOTE INTERNAL TAPER

FLAT WASHER /BRAID HEX NUT I BRAID CLAMP

V-GASKET

STEP 5

ADD THE 0- RING AND CONTACT RETAINER. CUT OFF THE PRIMARY
INSULATION FLUSH WITH THE KEL-F CONTACT RETAINER. CUT THE
CENTER CONDUCTOR APPROXIMATELY 08 INCH BEYOND THE
INSULATION. TIN THE CENTER CONDUCTOR WITH QQ-W-571C COMP
V-GASKET SN50 OR 60 SOLDER. SUPERIOR NO .30 FLUX MAY BE USED DURING
TINNING OF WIRE.

STEP 2
* O-RING

USE A THIN PROD TO UNBRAID AND STRAIGHTEN THE BRAID

STRANDS.

17
S T E P 6.

PRESOLDER CONTACT, PLACE THE CONTACT ON THE WIRE AND APPLY

HEAT UNTIL SOLDER FLOWS. OBSERVE THE FLOW OF SOLDER
THROUGH THE INSPECTION HOLE. THE PROPER TEMPERATURE EXISTS

RADIUS EDGE WHEN SOLDER APPEARS IN THE HOLE. CAREFULLY REMOVE ANY
EXCESS SOLDER ON OUTER SURFACE OF CONTACT.
HEX NUT V-GASKET KNIFE EDGE

NO GAP

INSPECTION HOLE

STEP 3.

USE A NYLON BRUSH TO COMB THE BRAID BACK OVER THE RADIUS
EDGE OF THE BRAID CLAMP. AN IDEAL BRUSH FOR THIS PURPOSE
CAN BE MADE BY TRIMMING THE BRISTLES OF A HARD NYLON
TRIM AS NECESSARY
TOOTHBRUSH. THE STRANDS SHOULD LIE APPROXIMATELY PAR.
ALLEL TO EACH OTHER.

STEP 7.
FLAT WASHER
BRAID CL A M P
PLACE CONTACT INSULATOR ON CONTACT. APPLY APPROX. 1 DROP
O F MIL-S-22473C G R A D E A OR AA SEALANT TO HEX NUT THREADS.
BRAID
INSERT CABLE ASSEMBLY INTO SHELL AND TORQUE DOWN TO 8 TO 10
I N -LBS USING CALIBRATED OR DIAL TYPE TORQUE WRENCH. THE
8 TO 10 IN-LBS APPLIED WILL SEAT THE BRAID CLAMP SHOULDER
AND CUT THROUGH THE V-GASKET*ON PLUGS, PLACE MOISTURE SEAL
IN CONNECTOR SHELL CHECK THE CONTACT ON PLUGS TO A ,125
MAXIMUM DIMENSION AND ON JACKS OR RECEPTACLES TO A ,050
HEX NUT ‘V-GASKET MAXIMUM DIMENSION.

SHELL (1211-404 PLUG ILLUSTRATED- .050 MAX. (JACKS OR RECEPTACLES]

STEP 4 OUTLINE OF OTHER COAX TYPE
CONNECTORS MAY VARY1 ,125 MAX. (PLUGS)

PRESS ON THE BRAID CLAMP COLLAR HALF WAY ON TO BRAID CLAMP

WITH LARGEST INSIDE DIA. OF BRAID CLAMP COLLAR AWAY FROM
CONTACT. NOTE IT IS MOST IMPORTANT AT THIS STEP TO ASSEMBLE
BRAID CLAMP CORRECTLY TO PREVENT SHEARING OF BRAID CONTACT (PIN TYPE
STRANDS. TRIM THE BRAID WITH THE RAZOR BLADE OR SHARP KNIFE ILLUSTRATED)
TO +.OOO - 025 WITHIN SHOULDER OF BRAID CLAMP. DO NOT USE
“DYKES” FOR TRIMMING. NO CRIMPING OR SQUEEZING TOOLS ARE T INSUL ATOR
TO BE USED TO INSTALL OR SEAT BRAID CLAMP COLLAR. THIS IS TO SEAL
PREVENT DAMAGE TO KNIFE EDGE OF BRAID CLAMP, ONLY)

* W h e n properly torqued, gap b e t w e e n n u t a n d b o d y a s s e m b l y s h o u l d n o t e x c e e d

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 FIGURE 3
S T E P 1.

SLlDE HEX NUT, FLAT WASHER, “-GASKET, AND CABLE CLAMP

RETAlNER OVER JACKET AS SHOWN. STRIP JACKET OFF CENTER
CONDUCTOR TO EXPOSE 0.080 INCH OF CONDUCTOR.

Delayed Maintenance

STEP 2.

SCREW CABLE C L A MP IN PLACE ON JACKET AS SHOWN PROVIDING

SPACE ON JACKET FOR 0 -RING. NOTE CABLE CLAMP RETAINER’S
POSlTlON MAY VARY BUT WlLL TlGHTEN DOWN WHEN THE ASSY IS
INSERTED INTO SHELL, PLACE O - R I NG AS S H O W N .
by TED FABER, Aerospace Safety Engineer, Senior

The companion article entitled, “Troubleshooting the

Hercules Fuel Quantity Indicating System” points out
that troubleshooting the fuel quantity indicating system
requires strict adherence to all safety precautions when
checking the system. This is also true when repairs are
STEP 3
required and is especially important when repair involves
the Amphenol 16.5 series fuel quantity indicator harness
TIN THE CENTER CONDUCTOR WITH 00-W-571C COMP SN50 OR 60
SOLDER. PRESOLQER CONTACT, PLACE THE CONTACT ON THE WIRE
connector plugs.
AND APPLY HEAT UNTIL SOLDER FLOWS. OBSERVE THE FLOW OF
SOLDER THROUGH THE INSPECTION HOLE. THE PROPER TEMPERA.
18 TURE EXISTS WHEN SOLDER A P P E A RS IN THE HOLE. CAREFULLY
The fuel quantity indicating system is designed as an
REMOVE ANY EXCESS SOLDER ON OUTER SURFACE OF CONTACT. electrically inert capacitance system, specifically designed
to eliminate any possibility of arcing from electrically
charged components within the system. However, when
careful attention is not observed during repair or
reinstallation of these connectors, it is possible to route
11.5 volts to the fuel tank through the shielded coaxial
cable. This can be accomplished through misalignment of
the connector pins or otherwise causing the wire shielding
to contact the 1 15-volt AC pin. On one occasion, an
STEP 4
explosion occurred when electrical power was restored
PLACE CONTACT INSULATOR ON CONTACT, APPLY APPROX. 1 DROP after maintenance had been performed on the Number
OF MIL-S-22473C G R A D E A O R A A S E A L A N T T O H E X N U T T H R E A D S .
IN S E RT CA B LE A SSEM B LY INT O S HE L L A ND T OR QUE D OW N TO 8T0 10 Four tank fuel quantity system. Investigation revealed
INCH-LBS. USlNG CALIBRATED OR DIAL TYPE TORQUE WRENCH* ON
PLUGS, PLACE MOISTURE S E A L IN CONNECTOR SHELL. CHECK THE
that an instrument specialist was troubleshooting the
CONTACT O N PLUGS T O A ,125 MAXIMUM DIMENSION AND ON JACKS indicating system as a result of a fuel quantity write up.
OR RECEPTACLES TO A ,050 MAXIMUM DIMENSION. 00 NOT CHECK
CONTACT DlMENSlONS ON GLASS SEAL BULKHEAD FEED THRU JACKS
External power was disconnected and then reconnected
(1244 SERIES) SlNCE THE EXTERNAL CONTACT I S POSITIONED DURING after the MD-2A fuel tester was used. The specialist was
MANUFACTURE OF SHELL.
in the process of visually checking the fuel quantity gage
wiring, with the gage removed from the overhead panel
mounting socket, and with the plug connected, when the
explosion occurred. The explosion ruptured the fuel tank
and caused extensive structural wing damage.

In this mishap it was found that during assembly of the

Amphenol connector, the retainer ring was not used. The
absence of the retainer ring allowed the plug socket to
move outward from the plug shell, disengaging the socket
keyway and permitting the socket to rotate approxi-
mately 120 degrees before mating. This allowed pin “J”

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..Can Give You A

in the connector to contact receptacle “B” in the socket, Both mishaps could have been avoided by carefully
allowing 115 volts to pass from pin “J”, which is common following procedures contained in service manuals and
ground, to the coaxial cable shield. When 1 15 volts was having a better understanding of the fuel quantity
applied to the system, a ground, through a fault in the indicating system. Failure of the indicator to self test or
outer covering of the coaxial cable, was obtained, and failure of the indicator to display proper fuel quantity
arced to aircraft structure, igniting fuel fumes in the tank. should have alerted the flight crew and maintenance
personnel to the possibility of a faulty connector plug.
In a similar manner an explosion occurred in the Number
One tank of a Hercules as the aircraft was climbing to LOCKHEED RECOMMENDS the following safety pre-
altitude for an extended over water mission, The cautions be adhered to during operation of the fuel
explosion resulted in an extensive wing fire and the crew quantity indicating system:
was forced to land the aircraft in a nearby corn field with
the landing gear retracted. After landing, the crew Failure of the indicator to test is indicative of a
evacuated the aircraft safely and the local Fire malfunction in the fuel quantity indicating system.
Department extinguished the fir-e. Maintenance action should be taken. If maintenance
is not complete, pull and pin the circuit breaker for
In this accident, delayed maintenance to correct repeated that indicator. Failure to comply may result in high
write ups against the Number One tank fuel quantity voltage being routed to the fuel tank which could
indication played a vital role. Over a period of two cause an explosion.
months the indicator was reported for reading “off scale”
a number of times. Each time the discrepancy was Fuel quantity indicators should not be removed or
corrected by resoldering the plug connections but the changed in flight. If a fuel quantity indicator
corrective action taken did not eliminate the problem. malfunctions or fails the press to test check, pull the
The last time, maintenance action to correct the respective circuit breaker and leave it out. If a fuel
malfunction was interrupted by an operational com- quantity indicator circuit breaker pops, do not
mitment to use the aircraft. The plug was hastily attempt to reset it. Failure to comply may result in
reassembled and connected to the indicator. The fuel high voltage being routed to the fuel tank which
quantity circuit breaker was pulled and the flight engineer could cause an explosion.
was verbally advised to keep the circuit breaker pulled.
This advice was passed on from one flight engineer to After landing write up the discrepancy and have
another for a time but this communications system finally maintenance correct the problem, NOW! Tomorrow may
broke down and the circuit breaker was pushed in prior to be too late!
the last flight. When this occurred 11 5-volt current was
directed to the Number One fuel tank. When sufficient
fuel had been consumed from the tank to create an
explosive atmosphere, arcing between a fault in the
coaxial cable and internal wing structure resulted in the
subsequent explosion. Later examination of the con-
nector plug revealed the 11 5-volt wire was in contact with
the coaxial shield and the shield was not grounded to the
case.

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 How

by J. S. RENO, Service Engineer, Hamilton Standard discharge, providing ideal bearing operating temperatures.
The bearings are lubricated by means of capillary wicks
which draw oil from a small reservoir. The wicks wipe the
SOURCE OF COOLING for the JetStar air conditioning oil onto tapered sections of the shaft which, through
20
system is the refrigeration package designed and centrifugal action, sling the oil as a fine mist into the
manufactured by Hamilton Standard, a division of United bearings.
Aircraft Corporation.
Here are inspection, maintenance, and overhaul recom-
Two refrigeration packages, employed in parallel, convert mendations for the JetStar refrigeration unit.
high temperature, high pressure engine bleed air to
conditions providing a comfortable environment in the
JetStar’s cabin and flight deck.
INSPECTION OF OIL SUMP
Each refrigeration package is a two-stage cooling device
consisting of a heat exchanger and a turbine-fan unit,
sometimes referred to as an air cycle machine. The heat At the end of each 500 hours of flying time, the
exchanger provides initial cooling by transferring heat turbine-fan oil sump should be inspected for oil level. (See
from the bleed air to ambient ram air which passes editor’s notes following article.) Look at the translucent
through the heat exchanger and is then dumped plastic oil sump while it is installed on the package. Don’t
overboard. The second stage of cooling is accomplished add oil if its addition would result in its overflowing the
with the turbine-fan. Cooling is obtained as the air sump’s spouts; any level less than full will require addition
expands through the turbine where heat is converted into of MILL-6085A oil.
mechanical energy. This energy is dissipated through the
fan as it helps to move the ram air through the heat If oil is added, the filler plug preformed packing, P/N
exchanger. Acting primarily as a load for the turbine, the MS28778-2 should be replaced.
fan serves a dual purpose in that it also induces air flow
through the ambient side of the heat exchanger when the The sump should also be inspected for the accumulation
aircraft is moving too slowly to generate ram flow. of water (considered normal when high humidity ambient
conditions prevail). Any water present should be removed
The shaft on which the turbine and fan are mounted is with a suction syringe. Since atmospheric and operating
supported by two ball bearings, spaced on one end of the conditions determine the rate of water accumulation, the
shaft and contained within the bearing cartridge. The period for sump inspection for the presence of water must
cartridge extends into the cold air of the turbine be established by each operator.

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Previous Page Table of Contents Next Page
 REPLACEMENT OF THE TURBINE- REPLACEMENT ON OVERHAUL INTERVAL
FAN ASSEMBLY
The turbine-fan should be overhauled each 1500 hours of
Replacement of the turbine-fan assembly may be flying time. (See editor’s notes following article.) The
accomplished as follows: heat exchanger may continue in service.

1. Remove the oil through the filler port of the sump of

the turbine-fan with a suction-type syringe. CAUTIONARY CONSIDERATION

Handling of the package with oil in the sump should be

2. Remove the two bolts and washers at the turbine
held to a minimum, and only with the sump in down
inlet/bleed air duct junction.
position. It is preferred that the sump be serviced after
3. Decouple the Marmon clamp between the turbine-fan the package is installed in the aircraft, and the oil be
and the heat exchanger and remove the turbine-fan. removed with a syringe prior to removal of the package
from the aircraft. The package should never be shipped
4. When installing the new turbine-fan, replace the two with oil in the sump.
preformed packings, P/N 69490B218 at the turbine
inlet/bleed air duct and P/N 69490B247 between Should the package be inverted with oil in the sump, the
turbine-fan and heat exchanger. Attach the Marmon oil could be introduced into the air passageways, which
clamp loosely, line up the bleed air duct to turbine will result in smoke or fumes in the conditioned air. This
inlet, install the two bolts, secure the Marmon clamp would require removal of the turbine-fan assembly and
and lockwire as required. return to an overhaul facility for thorough cleaning.

5. Service the oil sump with MIL-L-6085A oil after the When installing a turbine-fan assembly or refrigeration
package is installed in the aircraft. package in the aircraft, make sure that the oil sump is

22

TURBINE WHEEL

BEARING SLEEVE NUT

(NOT TO BE R E M O V E D

Cutaway of
JetStar Turbine-Fan
Assembly

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filled for at least three hours prior to running the pack- On rare occasions, it has happened that, during the “wear
age. The lubrication wicks must be saturated with oil for in” period of earlier model refrigeration units, the rim of
this minimum time period before they will provide the turbine wheel stuck in the cadmium seal in the nozzle
adequate lubrication to the bearings. plate. Rubbing here may occur for as long as 500 hours
of operation before the wheel “seats in” to the seal. If
Hamilton Standard provides a turbine-fan exchange attempts to start the refrigeration unit fail with the
service for the repair and overhaul needs of all JetStar engines at full RPM, and there is reason to believe that
operators. Participation in this Exchange Program enables non-rotation is due to seal drag, you can try a method of
an operator to obtain a zero time turbine-fan in advance applying mechanical torque that has been approved.
of removal of a unit in need of repair or overhaul. This
ability to secure replacement turbine-fans in anticipation The unit must be removed from the airplane, the turbine-
of scheduled removals minimizes maintenance down time. fan separated from the heat exchanger, and torque up to
Reprint From AirLifters Vol. 1, No. 4
100 inch-pounds applied to the fan nut in the direction of
normal rotation. The oil level in the reservoir should be
adequate during any run attempts; and, remember to keep
EDITOR’S NOTES the reservoir positioned down at all times when the unit is
removed, as pointed out in your Maintenance Manual.
The JetStar Handbook of Operating and Maintenance
Instructions (HOMI) published by Lockheed specifies that
After freeing the rotor, a bench run can be made with
the lubricating oil be changed every 500 hours. Any oil
bleed air, if available, or with a drill motor and a flexible
available that conforms to MIL-L-6085A can be used.
coupling such as a hose clamped to the fan nut.
This precautionary maintenance against contamination
contributes to more hours between overhaul. Other While the earlier configuration turbine fans, P/N 584395,
factors have helped to increase the TBO to 5,000 hours as were susceptible to turbine wheel/cadmium seal binding,
specified in the JetStar Operator’s Maintenance Report. the later configuration turbine fans, P/N 726638-1,
However, the manufacturer recommends a TBO of 1,500 contain an improved seal arrangement which is not sus-
1
hours or 2 / 2 years, whichever occurs first. ceptible to binding. Thus, if a later configuration unit
does not rotate while being subjected to full engine bleed
We wish to elaborate on the approach to the problem of a pressures, it should be removed from service and returned
“frozen” turbine wheel. Lockheed has also heard field 23
to an overhaul facility for investigation.
reports that indicate attempts were made to unstick
turbine rotors by pushing o n the fan blades. Damage to
these elements, although not apparent, can be destructive
at operating speeds near 60,000 RPM. If the rotor sticks
on a high time refrigeration turbine, the unit should be
replaced.

HOW THE 1867TH FCS LICKED A TURBINE

PROBLEM
by E. P. CARY, JR., Field Service Representative

THE 1867th FACILITY CHECKING SQUAD- Sustained low altitude flight causes heavy water
RON at Clark Air Base in the Philippines flies condensation in the cooling turbine oil reservoir,
JetStars l o w a n d s l o w i n h o t a n d h u m i d ultimately causing turbine bearing failure.
environments.
To lick this special problem, the 1867th FCS
These hard-flying pilots have to fly low and slow instituted a special maintenance procedure -
to perform their mission, checking navigational removing and replacing reservoir oil every 25
facilities in Southeast Asia - such as Precision flight hours. As a result, turbine bearing life was
Approach Radar and Tacan - to make sure they materially improved.
are functioning properly for the safety of other
aircrews. Reprint From AirLifters Vol. 1, N O . 4

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