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FUEL MANAGEMENT PANEL

MAINTENANCE MANUAL
TO HOLDERS OF FUEL MANAGEMENT PANEL COMPONENT MAINTENANCE
MANUAL P/N 727-0860/01.01

Revision N°2 Dated October/06/2009

In this issue the revision code of each manufactured part number has been deleted,
so the P/N format has been changed from XXX-YYYY/ZZ.VV into XXX-YYYY/ZZ
The list of the pages affected from this revision are outlined below with a description
of the change. Please remove and insert affected pages in accordance with the
“List of Effective Pages”

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HIGHLIGHTS

Chapter/Section Page No Description of change Effectivity

Title T1 Revised to reflect this revision


All
Warranty/Liability
SWLA 1 Revised to reflect this revision
Advisory All

Record of
RR 1 Revised to reflect this revision
Revision All

List of Effective
LEP1-LEP 2 Revised to reflect this revision
Pages All

INTRODUCTION INTRO 3 Revised to reflect this revision

Table of
TOI 1 Revised to reflect this revision
Illustrations All

Description and From 1 to 4, 6 P/N changed


Operation All

Testing and 101, 102,106 P/N changed


Fault Isolation From 111 to 129 P/N changed
From 136 to 146 Figure changed
All
Inspection 501, 503 P/N changed

Disassembly 301, 302 P/N changed


All

Repair 603 P/N changed


From 605 to 609 P/N changed
All
From 611 to 616 P/N changed
From 619 to 620 P/N changed

Assembly Page,701, 702, P/N changed


703 All

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Fits and 802 P/N changed


All
Clearances

Illustrated Parts From 1001 to P/N changed


List 1007
From 1011 to Add new figure All
1022

Discard previous issues of Component Maintenance Manual 28-10-01 and replace


with this issue dated Oct/06/2009.

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HIGHLIGHTS-4
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SIRIO PANEL S.p.A.

Component Maintenance Manual

With

Illustrated Part List

FUEL MANAGEMENT PANEL

P/N SIRIO PANEL 727-0860/01.01


P/N AERAZUR 508618

ORIGINAL ISSUE:
Sirio Panel S.p.A. Copyright 2009
Loc. Levanella Becorpi
50025 Montevarchi
Arezzo – ITALY
Tel. 055-913671
Fax. 055-9180463

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WARRANTY/LIABILITY ADVISORY

Sirio Panel is not responsible for a FUEL MANAGEMENT PANEL P/N 727-0860/01.01, that
is not maintained and/or repaired in accordance with Sirio Panel published instructions and
repair authorization. Sirio Panel is not responsible for special tools and test equipment
made by other companies.

Incorrectly repaired components can cause problems in airworthiness or decrease the life
of components. Incorrectly made special tooling or test equipment can cause damage to
product components or give unsatisfactory results. Equipment or parts not repaired or
made by facilities approved by Sirio Panel can increase the risk of death or injury to
persons. It can also cause component failures and secondary damage and can cancel
warranties underwritten by Sirio Panel.

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A. RECORD OF REVISIONS

REVISION REVISION ENGINEER DESCRIPTION OF DATE BY


NUMBER DATE APPROVAL CHANGE INSERTED (INITIAL)
1 Sep/20/2007 Original Edition

2 Oct/06/09 First revision

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B. TEMPORARY REVISION RECORD

DATE
TEMP. ISSUE
INCORPORATED INSERTED REMOVED
REV.NO. DATE
INTO CMM
DATE BY DATE BY

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C. SERVICE BULLETIN RECORD

DATE INCORPORATED
SERVICE BULLETIN OTHER DIRECTIVES
INTO MANUAL

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D. LIST OF EFFECTIVE PAGES

Chapter/Section PAGE REV. NR DATE


T-1 2 Oct/06/09
Title Page
T-2 1 Sep/20/2007
SWLA-1 2 Oct/06/09
Safety Advisory
SWLA-2 1 Sep/20/2007
RR-1 2 Oct/06/09
Record of revisions
RR-2 1 Sep/20/2007
TR-1
Temporary Revision 1 Sep/20/2007
TR-2
SB-1
Service Bulletin 1 Sep/20/2007
SB-2
LEP-1
List of effective pages 1 Sep/20/2007
LEP-2
TOI1 2 Oct/06/09
Table of Illustrations
TOI2 1 Sep/20/2007
TC-1
Table of contents 1 Sep/20/2007
TC-2
INTRO 1 to INTRO 2 1 Sep/20/2007

Introduction INTRO 3 1 Oct/06/09

INTRO 4 to INTRO 12 1 Sep/20/2007

From 1 to 4 2 Oct/06/09

5 1 Sep/20/2007
Description and Operation
6 2 Oct/06/09

From 7 to 10 1 Sep/20/2007

From 101 to 102 2 Oct/06/09

From 103 to 105 1 Sep/20/2007


Testing and fault Isolation
106 2 Oct/06/09

From 107 to 110 1 Sep/20/2007

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Testing and fault Isolation From 111 to 129 2 Oct/06/09

From 130 to 135 1 Sep/20/2007

From 136 to 146 2 Oct/06/09

From 501 to 503 2 Oct/06/09


Inspection
From 502 to 504 1 Sep/20/2007

Disassembly From 301 to 302 2 Oct/06/09

Cleaning From 401 to 402 1 Sep/20/2007

From 601 to 603 1 Sep/20/2007

From 605 to 609 2 Oct/06/09

610 Sep/20/2007
Repair
From 611 to 616 2 Oct/06/09

From 617 to 618 1 Sep/20/2007

From 619 to 620 2 Oct/06/09

From 701 to 703 2 Oct/06/09


Assembly
704 1 Sep/20/2007

801 1 Sep/20/2007
Fits and Clearances
802 2 Oct/06/09
Special Tools, Fixtures an
From 901 to 902 1 Sep/20/2007
equipment materials
From 1001 to 1007 2 Oct/06/09

Illustrated Part List From 1008 to 1010 1 Sep/20/2007

From 1011 to 1022 2 Oct/06/09

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E. TABLE OF ILLUSTRATIONS

PAGE
Fig. 1 S-92 FUEL MANAGEMENT PANEL 5
Fig. 2 FMP Replaceable Spare Parts 7
Fig. 3 S-92 FUEL MANAGEMENT PANEL 9
Fig. 101 Test Bench interconnections for Function testing. 104
Fig. 102 FMP STTE APSW: Main Form 107
Fig. 103 FMP STTE APSW : TX Status Label form. 108
Fig. 104 FMP STTE APSW : Edit fuel quantity form. 108
Fig. 105 Wiring test. 110
Fig. 106 28Vdc POWER CONSUMPTION (Flowchart 1) 135
Fig. 107 5Vdc PANEL POWER CONSUMPTION (Flowchart 2) 136
Fig. 108 ARINC 429 TX TEST (Flowchart 3) 137
Fig. 109 FMP-FCU COMMUNICATION TEST (Flowchart 4) 138
Fig. 110 PRE-CHECK SWITCH TEST (Flowchart 5). 139
Fig. 111 MODE OFF TEST (Flowchart 6). 140
Fig. 112 MODE R/D TEST (Flowchart 7). 141
Fig. 113 MODE MANUAL TEST (Flowchart 8) 142
Fig. 114 MODE AUTO TEST (Flowchart 9). 143
Fig. 115 HLSOV-PWR SHORT CIRCUIT PROTECTION PANEL (Flowchart 10). 144
Fig. 116 MANAGEMENT VALVE FAILURE (Flowchart 11). 145
Fig. 117 VERIFICATION OF THE FUEL MANAGEMNT PANEL 723-5345/01 (Flowchart
12). 146
Fig. 501 Visual check (Flowchart 1) 503
Fig. 502 Dimensions and Weight. (Flowchart 2) 504
Fig.801 S-92 FUEL MANAGEMENT PANEL 727-0860/01.01 802
Fig.901 Test Box 728-0225/01 902

IPL
Fig 1 Exploded view (Part 1) 1004
Fig 2 Exploded view (Part 2). 1006
Fig 3 Cabling assembly. 1008
Fig 4-electric connections 1010
Fig 5 Schematics Diagrams 724-1523/01 Sheet 1 1011
Fig 6 Schematics Diagrams 724-1523/01 Sheet 2 1012
Fig 7 Schematics Diagrams 724-1523/01 Sheet 3 1013
Fig 8 Schematics Diagrams 724-1523/01 Sheet 4 1014
Fig 9 Schematics Diagrams 724-1523/01 Sheet 5 1015
Fig 10 Schematics Diagrams 724-1524/01 Sheet 1 1016
Fig 11 Schematics Diagrams 724-1524/01 Sheet 2 1017
Fig 12 Schematics Diagrams 724-1524/01 Sheet 3 1018
Fig 13 Schematics Diagrams 724-1524/01 Sheet 4 1019

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Fig 14 Schematics Diagrams 724-1524/01 Sheet 5 1020
Fig 15 Schematics Diagrams 724-1524/01 Sheet 6 1021
Fig 16 Schematics Diagrams 724-1524/01 Sheet 7 1022

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F. TABLE OF CONTENTS

PAGE EFFECTIVITY
INTRODUCTION INTRO-1 ALL

DESCRIPTION AND OPERATION 1 ALL

TESTING AND FAULT ISOLATION 101 ALL

AUTOMATIC TEST REQUIREMENTS (ATLAS) N/A -

DISASSEMBLY 301 ALL

CLEANING 401 ALL

INSPECTION 501 ALL

REPAIR 601 ALL

ASSEMBLY 701 ALL

FITS AND CLEARANCES 801 ALL

SPECIAL TOOLS, FIXTURES AND EQUIPMENT


901 ALL
MATERIALS

ILLUSTRATED PART LIST 1001 ALL

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G. INTRODUCTION

TABLE OF CONTENTS

PAGE
1. General Information INTRO-3
2. Glossary of Abbreviation and Symbols INTRO-5
3. List of Approved Distributors INTRO-7
4. List of Authorized Repair Stations INTRO-9
5. Identifying Revised Material INTRO-11
6. Summary of Maintenance Recommendations INTRO-11

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1. GENERAL INFORMATION

(a) This manual is written to the ATA Specification 100 and the AECMA
Simplified English standards.
(b) This manual describes maintenance on components in a workshop. It does
not describe maintenance on components when they are installed in the
aircraft.
(c) Only approved technicians with the necessary skills are allowed to perform
maintenance as described in this manual.
(d) Aircraft Maintenance Task Oriented Support System (AMTOSS) is not
supported in this manual.
(e) This manual provides maintenance instructions with illustrated parts
breakdown for the FUEL MANAGEMENT PANEL. Sirio Panel S.p.A
provides this component and its issue (ISSUE 2) has been dated: October
2009. Comments, suggestion and remarks or request for further
information may addressed to:

Sirio Panel S.p.A.


Loc. Levanella Becorpi
52025 Montevarchi
Arezzo – ITALY

(f) This manual is divided into separate sections as follows:

Title Page Disassembly Cleaning


Record of revisions Check
Record of Temporary Revisions Repair
Service Bulletin List Assembly
List of Effective Pages Fits and Clearances
Table of Contents Illustrated Part List
Introduction Special Tools, Fixtures and Equipment
Description and Operation Testing and Fault isolation

(g) To facilitate use of this manual, data that is peculiar to a specific


configuration is presented separately by subsection within each major
section of the manual. The Table of Contents at the beginning of the
manual tabulates all major sections. A more detailed Table of Contents is
provided at the beginning of each section.
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(h) Throughout the manual pays particular attention to the WARNINGS,
CAUTIONS, and NOTES; their intentions are as follows:

WARNING: TO CALL ATTENTION TO METHODS AND PROCEDURES WHICH


MUST BE FOLLOWED PRECISELY TO AVOID INJURY TO PERSONS.

CAUTION: TO CALL ATTENTION TO METHODS AND PROCEDURES WHICH


MUST BE FOLLOWED TO AVOID DAMAGE TO EQUIPMENT.

NOTE: To call attention to methods that make the job easier.

(i) Page Intro-4 consists of a list of Abbreviations and Symbols used


throughout this manual.
(j) All weights and measures quoted in this publication are expressed in S.I
units of measure.
(k) This manual will be revised as a necessary to reflect current information.

NOTE: The Depot level includes the maintenance tasks, repair tasks that require
use of some specific tools. This maintenance level is intended for and its
allowable repair stations.

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2. GLOSSARY OF ABBREVIATIONS AND SYMBOLS

U.U.T. Unit Under Test


FMP FUEL MANAGEMENT PANEL
IPL Illustrated Part List
PN Part Number
R/R Remove/Replace
T.B. Test Box

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3. LIST OF APPROVED DISTRIBUTORS

NAME ADDRESS

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4. LIST OF AUTHORIZED REPAIR STATIONS

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5. IDENTIFYING REVISED MANUAL

NOTE: A revision to a page is defined as any change to the printed matter that
existed previously.

(a) A. Revisions, additions and deletions shall be identified by a vertical black


line along the left hand margin of the page opposite only that portion of the
printed matter that has changed.
(b) B. A black line in the left hand margin opposite the page number and date
will indicate that the text was unchanged but the material was relocated to
a different page.
(c) C. For the detailed parts list an individual code letter «R», instead of a
vertical black line, shall be used on each line to identify revisions.
(d) D. A revision that constitutes a complete manual changes is void of all
black lines in the left-hand margin to eliminate confusion. Each page of a
complete manual change is assigned the new revision date.

6. SUMMARY OF MAINTENANCE RECOMMENDATIONS

RECOMMENDATION REFERENCE
(1) Verify incorporation of all outstanding
Service Bulletins and Service Information
Letters.

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1. Description and Operation


This manual contains the information required to understand the purpose, the
operation and the maintenance of the FUEL MANAGEMENT PANEL issue
identified by P/N-727-0860/01.01 and manufactured by Sirio Panel S.p.A.
A. Introduction
The hardware composition of the FUEL MANAGEMENT PANEL, involved in the
maintenance procedures, is reported in the following table. The hardware
composition is provided to enable the identification only of the parts involved in the
test and repair procedures of the FUEL MANAGEMENT PANEL.

For each S-92 FMP item of interest, the following information is provided:

- Nr: progressive number of item in the table.


- Level: hierarchic level of the item inside the equipment structure tree.
- Vendor Code (Vendor Name): identification code allocated by the
Vendor, the Vendor name is reported in brackets. When existing,
instead of the Vendor Code, is reported the Unified Code.
- OEM Code:. Original Equipment Manufacturer Code, identification
code allocated by Sirio Panel to the item.The structure of the
identification code for each manufactured part is contituted by the
format such as “XX-YYYY/ZZ.VV” where “XX-YYYY/ZZ” digits
represent the code and “.VV” digits represent the revision of the
code.The revision of the code is not included in the table, because
different revision of manufactured item with the same code are fit, form
and function interchangeable.
- Original Description: name of the item in the Italian language (this is
the name by which the item is identified in Sirio Panel documentation).
- English Description: translation in the English language of the
Original Description.
- Q.ty: quantity of the specified item.

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S-92 FUEL MANAGEMENT PANEL Composition Table

Vendor Code
Original English
Nr. Lev (Vendor OEM Code Q.ty
Description Description
Name)
S-92 FUEL S-92 FUEL
MANAGEMENT MANAGEMENT
727-0860/01.01 PANEL PANEL 1
P/N P/N
727-0860/01.01 727-0860/01.01
PANNELLO FUEL S 92 FUEL
1 1 - 723-5345/01 MANAGEMENT MANAGEMENT 1
S92 PANEL
ASSIEME FUEL
CONTROPANNELL MANAGEMENT
2 1 - 921-2166/01 1
O FUEL COUNTERPANEL
MANAGEMENT ASSEMBLY
MANOPOLA D BLACK KNOB
3 1 - 921-0104/86 GRANDE TRAPEZIUM 1
TRAPEZIA NERA SHAPE
ASS. COLONNINO TRIANGULAR
4 1 - 921-2179/01 TRIANGOLARE STAND OFF 4
L100 ASSEMBLY
UNI 7688 SCREW INOX INOX SCREW
5 1 61550-33/005 8
DIN965 A TSP/C M3X6mm M3X6mm
ASS. PCB FUEL
6 1 - 724-1523/01 CONNETTORI CONNECTORS 1
FUEL PCB ASSEMBLY
ASS. PCB FUEL CONTROL
7 1 - 724-1524/01 1
COMANDO FUEL PCB ASSEMBLY
TARGHETTA IDENTIFICATION
8 1 - 920-0237/01 1
AUTOADESIVA LABEL
FUEL
CABLAGGIO FUEL
9 1 - 926-0642/01 MANAGEMENT 1
MANAGEMENT
CABLING
RAYCHEM WIRE
10 2 55550-09/089 WIRE 22_.38mm**2 -
55A11-22-9 22_.38mm**2
RAYCHEM
SHEATH
TERMOFIT SHEATH
11 2 58287-02/075 POLYOLEFIN -
RNF-3000-3/1- POLYOLEFIN 3mm
3mm
0

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Vendor Code
Original English
Nr. Lev (Vendor OEM Code Q.ty
Description Description
Name)
12 ELEMATIC CABLE
2 67173-01/002 CABLE ACC__m**2 7
5203 ACC__m**2
RAYCHEM
13 2 67123-03/024 SPLICE SPLICE 2
D100-31
MECH MECH
14 2 MS24658-23F 67516-41/009 3
SWITCH_V_A_1 SWITCH_V_A_1
COMMITAL CON. COAX F DA PANEL COAXIAL
15 2 67352-73M004 1
CX 1002 PANN. CONNECTOR
GRAYHILL GRAYHILL
16 2 44M90-02-01- 44M90-02-01- ROTARY SWITCH ROTARY SWITCH 1
04N 04N

17 2 AMP 320553 55820-47/001 TERMINAL TERMINAL 6

NICOMATIC NICOMATIC FUEL CONTROL


18 2 CONNETTORE 1
222C20M11 222C20M11 CONNECTOR
NICOMATIC
19 3 C13064-P PIN CONNETTORE CONNECTOR PIN 20
C13064-P
UNI 7687 DIN SCREW INOX INOX SCREW
20 1 61530-27/005 4
7985A TCC/C M2.5X6mm M2.5X6mm
INOX FLAT
ISO 7092 WASHER PLANE
21 1 61170-03/127 WASHER M2.5- 4
DIN 433 INOX M2.5-5mm
5mm
INOX ELASTIC
UNI 1751 B WASHER EL INOX
22 1 61170-06/123 WASHER M2.5- 4
DIN 127 B M2.5-5.1mm
5.1mm
GUARNIZIONE FUEL
23 1 - 920-9122/01 FUEL MANAGEMENT 1
MANAGEMENT GASKET
INOX FLAT
ISO 7092 WASHER PLANE
24 1 61170-03/128 WASHER M3- 4
DIN 433 INOX M3-6mm
6mm
GUSCIO FUEL PAINTED
25 1 - 928-0883/01 1
VERNICIATO FUEL COVER
INOX ELASTIC
UNI 1751 B WASHER EL INOX
26 1 61170-06/124 WASHER M3- 4
DIN 127 B M3-6.2mm
6.2mm
GUARNIZIONE
2100-01-D50- VANGUARD
27 1 - VANGUARD 1
ORA-NPS-SPL GASKET L410mm
L410mm
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Vendor Code
Original English
Nr. Lev (Vendor OEM Code Q.ty
Description Description
Name)
28 UNI 7687 DIN SCREW INOX INOX SCREW
1 61530-27/036 4
7985A TCC/C M3X8mm M3X8mm
29 1 LOCTITE 242 57510-04/012 LOCTITE LOCTITE -
DOW
CORNING SILICONE SILICONE
29 1 57510-11/002 -
3145RTV MIL- ADHESIVE ADHESIVE
A-46146

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B. Functional and Operational Description

(1) GENERAL
The FUEL MANAGEMENT PANEL is a box that must be installed in the pilot
cockpit of the helicopter Sikorsky S-92.
On the front panel of the FMP there are:

(a) Two positions toggle switch, locked in “OPEN” position, SW01.


(b) Two positions toggle switch, locked in “OPEN” position, SW02.
(c) Two positions toggle switch, locked in “OPEN” position, SW03.
(d) Four positions rotary switch, SW04.

a
b
c
d

Fig. 1 S-92 FUEL MANAGEMENT PANEL

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(2) S-92 FUEL MANAGEMENT PANEL Replaceable Spare Parts.

Fig. 2 shows the Replaceable Spare Parts of the FUEL MANAGEMENT PANEL.

ITEM 1) BLACK KNOB TRAPEZIUM SHAPE, P/N 921-0104/86.


ITEM 2) S-92 FUEL MANAGEMENT PANEL, P/N 723-5345/01.
ITEM 3) FUEL PAINTED COVER, P/N 928-0883/01.
ITEM 4) IDENTIFICATION LABEL, P/N 920-0237/01.
ITEM 5) MECH SWITCH_V_A_1, P/N 67516-41/009 SW01.
ITEM 6) MECH SWITCH_V_A_1, P/N 67516-41/009 SW02.
ITEM 7) MECH SWITCH_V_A_1, P/N 67516-41/009 SW03.
ITEM 8) ROTARY SWITCH GRAYHILL, P/N 44M90-02-01-04N SW04.
ITEM 9) PANEL COAXIAL CONNECTOR, P/N 67352-73M004.
ITEM 10) FUEL MANAGEMENT GASKET, P/N 920-9122/01.
ITEM 11) FUEL CONTROL PCB ASSEMBLY, P/N 724-1524/01.
ITEM 12) FUEL CONNECTORS PCB ASSEMBLY, P/N 724-1523/01.
ITEM 13) FUEL CONTROL CONNECTOR, NICOMATIC, P/N 222C20M11.
ITEM 14) WIRE 22_.38mm**2, P/N 55550-09/089.
ITEM 15) CABLE ACC__m**2, P/N 67173-01/002.
ITEM 16) SPLICE, P/N 67123-03/024
ITEM 17) VANGUARD GASKET L410mm 2100-01-D50-ORA-NPS-SPL.

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13
15
16
6
5
17

10
12
11
14
7
9
8

2
1

Fig. 2 FMP Replaceable Spare Parts

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C. Technical data Summary.

(1) The outline drawing.

The Outline drawing of the S-92 FUEL MANAGEMENT PANEL is shown in Fig. 3.
The dimensions and weight are as follows:

Overall length:158mm MAX


Overall width: 100.84mm
Overall height: 133.35mm

Fixing dimensions:

Fixing width: 91.19mm


Fixing height: 104.9mm

Weight: lower than: 1.00 Kg.

(2) Environmental features.

(a) Temperature.

Operating Min. -40°C


Max. +70°C
Storage Min. -55°C
Max. +85°C

(b) Relative humidity

Operating Max. 95%

Storage Max. 95%

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FUEL MANAGEMENT PANEL


AUX REFUEL
OPEN
LH REFUEL RH REFUEL
OPEN OPEN
CLOSE

CLOSE CLOSE

AUX MODE SELECT


AUTO

J01 J02
REFUEL/DEFUEL OFF

MANUAL

SIRIO PANEL - A4582


P/N 727-0860/01
S/N Date

P/N 508618

Fig. 3 S-92 FUEL MANAGEMENT PANEL

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PAGE INTENTIONALLY LEFT BLANK

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2. Testing and Fault Isolation

A. Introduction

The execution of the S-92 FUEL MANAGEMENT PANEL test procedures,


described in the following paragraph, allows to highlight the failure symptoms
presented by the Unit Under Test.
In fact, if a test procedure is not successful, a troubleshooting procedure starting
from the failed test can be carried out to isolate the faulty item and to perform the
remove/replace activity.

CAUTION: Always use the APPLICATION ELECTROSTATIC-DISCHARGE SAFETY


PRECAUTIONS (according to EN100015/1or equivalent) NEAR
DEVICES SENSITIVE TO ELECTROSTATIC DISCHARGE. Always use
the suggested tools to perform testing procedures .Improper handling
might damage material.

(1) Test Equipment required.

The test equipment (both special and standard) required performing testing and
fault isolation activities are identified and described in the following.

(a) Special Test Equipment.


- Test Box 728-0225/01
- ACPCI Board 724-0758/01 equivalent to 724-0758/02.

(b) Standard Test Equipment.


- Double power supply variable DC 0-30V GW GPC3030D or equivalent
(able to supply min: 3A).
- Power Supply red cable:RS488-416 or equivalent.
- Power Supply black cable: RS488-422 or equivalent.
- Digital Multimeter Fluke mod.8010A or equivalent.
- PC Station Windows with the minimum Hardware configuration:
- Pentium 3 or more.
- RAM ≥ 512 MB.
- Operating system: Windows 2000 or Windows XP.
- PCI-CAN/2 interface board.

(c) TOOLS required.


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- No TOOLS REQUIRED for testing and fault isolation.

(d) Environmental conditions for testing


- Ambient temperature: 20°±5°C
- Pressure: 85 to 106 Kpa
- Relative humidity ≤85%

NOTE: All instrumentation must be kept under calibration conditions.

B. Power Consumption Testing.

(1) 28 Vdc Power Consumption.


(a) Set the Power Supply to 28Vdc±0.1V and switch it OFF.
(b) Connect the positive pole of the 28Vdc Power Supply to the Pin 1 of the
J01 connector of the U.U.T.
(c) Set the Multimeter as a Ammeter and connect it to the Power Supply.
(d) Connect the 28 Vdc return of the Power Supply, to the Pin 2 of the J01
connector of the U.U.T.
(e) On the U.U.T. set the three switches of the “FUEL MANAGEMENT PANEL”
section in OPEN position.
(f) On the U.U.T. turn the “AUX MODE SELECT” rotary switch out of the OFF
position.
(g) Switch ON the 28 Vdc Power Supply.
(h) Verify, on the Ammeter, that the current consumption is lower than
200mA+/10%.
(i) Switch OFF the Power Supply.
(j) If a test procedure is not successful, refer to Fig. 106 to execute the Fault
isolation procedure.
(2) 5 Vdc Panel Power Consumption.
(a) Set the Power Supply to 5Vdc±0.1V and switch it OFF.
(b) Connect the positive pole of the 5 Vdc Power Supply to the Pin 4 of the J01
connector of the U.U.T.
(c) Set the Multimeter as a Ammeter and connect it to the Power Supply.
(d) Connect the 5 Vdc return of the Power Supply, to the Pin 5 of the J01
connector of the U.U.T.
(e) Switch ON the 5 Vdc Power Supply.

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(f) Verify on the Ammeter that the current consumption is lower than 1.2+/-
10% A.
(g) Switch OFF the Power Supply.
(h) If a test procedure is not successful, refer to Fig. 107 to execute the Fault
isolation procedure.
C. Functional Testing.

NOTE: The following terms are used in the tables of the Functional Testing and
are defined as follows:

- Step Description: setting of the U.U.T and the instruments of the Test
Bench to execute the Functional Testing.
- Expected Results: response of the Test Bench that establish the
success or the failure of the Functional Testing.

(1) Test Set-up Data.

(a) Test Bench Set Up for Function testing.

The Test Bench for the execution of the Function testing procedures is shown in
Fig. 101

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28Vdc 5Vdc
FMP Power Supply Power Supply

FMP
Lighting
FMP Power Power

Arinc429

PC TEST
(FMP STTE)

Fig. 101 Test Bench interconnections for Function testing.

(2) Common test Procedures.


To shorten test procedures descriptions, all activities common to several tests have
been identified and described into the following paragraphs.In this way, whenever a
common procedure is required, the test description, indicates only the procedure
name (with the reference paragraph), omitting the single step descriptions of
activity.

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(a) FMP Start-Up Procedure.

Tab. 1, describes the steps necessary to power-up the FMP by means of the
test bench.

Step
Step Description Expected Results Remarks

Power supplies
Connect the 28Vdc and
must be configured
5Vdc power supplies
for
1 (switched-off), the PC Test
+28Vdc±0.1V/5A
and the FMP unit to the test
and +5V±0.1V /2A
box.
output values.
Set the 28VDC-PWR and
2 5VDC-LTNG switches to
OFF
Switch-on the power
3
supplies.
Connect a jumper at the
5VDC PWR-CONS jack.
4 Switch to on the 5VDC- LED ON
LTNG and check the
relevant ON Led status.
Connect a jumper at the
28VDC PWR-CONS jack.
5 Switch to on the 28VDC- LED ON
PWR and check the
relevant ON Led status.
Tab. 1

(b) FMP Shut-Down Procedure.


Tab.2 describes the steps necessary to power-down the FMP by means of
the test bench.

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Step
Step Description Expected Results Remarks

Switch to off the 28VDC-
1 PWR and check the LED OFF
relevant ON Led status.
Switch to off the 5VDC-
2 LTNG and check the LED OFF
relevant ON Led status.
Switch-off the power
3
supplies.
Tab.2

(c) HLSOV Power Supply Voltage Measurement Procedure.

Tab. 3 describes the steps necessary to measure power supply voltage of


HLSOV Primary and Secondary solenoids by means of the test bench.

Step
Step Description Expected Results Remarks

Connect the ground (black)
terminal of DMM to the
1
black jack of HLSOV-PWR-
SUP REFS section (J13).
Connect the signal (red)
terminal of DMM to the TP
2 (blue) jack of HLSOV-PWR-
SUP PRIMARY section
(J7).
Check voltage indication on PRIMARY Voltage
3 >27V
DMM measurement
Connect the signal (red)
terminal of DMM to the TP
4 (blue) jack of HLSOV-PWR-
SUP SECONDARY section
(J9).
>27V SECONDARY
Check voltage indication on
5 Voltage
DMM
measurement
Tab. 3

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(3) Equipment Set-up:


On PC Station, launch FMPSTTE executable file.
The window shown in Fig. 102 will appear: this is the application created for FMP
Arinc429 link management during execution.
This paragraph describes the FMP STTE application, whose main form is shown in
Fig. 102

Fig. 102 FMP STTE APSW: Main Form

The SW capabilities are the followings:

(a) Reception management (Health Status section):

Reception is always active.


All the fields of the Health Status section are updated with the last received
Health Status message.

(b) Transmission management (Transmitter section):

The transmission of all labels can be enabled by means of the selection of the
TX Enable check box (refer to Fig. 102 ).

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The content of label 350, 351, 354 and 355 can be set into the Tx Status Label
dialog window (refer to Fig. 103), opened by means of TX Status push button.
The FWD IAFS Fuel Quantity section allows managing the Label 260. It is
possible to enable/disable the label transmission (Enable check box), to override
a failure condition (Failure check box) and to set the fuel quantity (up/down
arrows of Edit Fuel Quantity dialog window reported in Fig. 104).
The Left Main Tank Fuel Quantity section allows managing the Label 256.
The Right Main Tank Fuel Quantity section allows managing the Label 257.

Fig. 103 FMP STTE APSW : TX Status Label form.

Fig. 104 FMP STTE APSW : Edit fuel quantity form.

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(4) ARINC429 TX TEST

(a) Set the Test Bench for the execution of the Function testing (Refer to test
Bench set up Para.2.C. (1) (a)).
(b) Perform the test according to Tab. 4.

Step
Step Description Expected Results Remarks

See the FMP Start-
1 Power Up the FMP Up Procedure
(Para 2. C. (2) (a).)
FMP Cold Start
FMPSTTE Health Status
Procedure.
section:
2 After 1 sec from Power Up To verify the FMP
Data Status = Not
TX Arinc 429
Computed
Communication.
FMPSTTE Health Status
section:
3 Wait at least 5 sec
Data Status = Normal
operation
Tab. 4

(c) If a test procedure is not successful, refer to Fig. 108 to execute the Fault
isolation procedure.

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Fig. 105 Wiring test.

(5) FMP-FCU Communication Test

(a) Set the Test Bench for the execution of the Function testing (Refer to test
Bench set up Para.2.C. (1) (a)).
(b) Perform the test according to Tab. 5.

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Step
Step Description Expected Results Remarks

Click on the TX Enable of
Enable the FMP-
the Transmitter section of
1 FCU
the FMPSTTE Apsw
Communication
windows.
FMPSTTE Health Status
section: To verify the FMP
2 After 1 sec from Power Up
FMP-FCU Communication RX Arinc 429.
= Change from FAIL to OK
Remove the TX Enable of
Disable the FMP-
the Transmitter section of
3 FCU
the FMPSTTE Apsw
Communication
windows.
FMPSTTE Health Status
section:
4 Wait at least 5 sec
FMP-FCU Communication
= Change from OK to FAIL
Click on the TX Enable of
Enable again the
the Transmitter section of
5 FMP-FCU
the FMPSTTE Apsw
communication
windows.
Tab. 5

(c) If a test procedure is not successful, refer to Fig. 109 to execute the Fault
isolation procedure.
(d) Set the multimeter in “BEEP” function and verify the electric connections,
refer to Fig 4 in the IPL.

NOTE: For wires test, dodge the sheath from the component pins without
removing it, as far is possible. The dodged sheath must allow the access
of the multimeter pins (Refer to Fig. 105).

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(6) Pre-Check Switch Test
(a) Set the Test Bench for the execution of the Function testing (Refer to test
Bench set up Para.2.C. (1) (a)).
(b) Perform the test according to Tab. 6.

Step
Step Description Expected Results Remarks

See the FMP Start-
1 Power Up the FMP Up Procedure
(Para 2. C. (2) (a).)
Time required at
start-up to get
2 Wait at least 1 sec
control of discrete
signals.
Move AUX MODE SELECT
3 rotary switch in OFF
position
Move all AUX REFUEL
4 Toggles switches to OPEN
position
Verify all the Primary & FMP Test Bench:
Secondary HLSOV Power PRIM.-HLSOV-PWR-RTN
Return pins are connected RH LED ON
to GND PRIM.-HLSOV-PWR-RTN
LH LED ON
PRIM.-HLSOV-PWR-RTN
5 IAFS LED ON
SEC.-HLSOV-PWR-RTN
RH LED ON
SEC.-HLSOV-PWR-RTN
LH LED ON
SEC.-HLSOV-PWR-RTN
IAFS LED ON
Verify 28V is not applied on FMP Test Bench:
the Primary & Secondary HLSOV-PWR-SUP
HLSOV Power Supply pins PRIMARY LED OFF
7
HLSOV-PWR-SUP
SECONDARY LED
OFF
Move LH REFUEL HLSOV
8
Toggle to CLOSE position

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Step
Step Description Expected Results Remarks

9 Verify all the Primary & PRIM.-HLSOV-PWR-RTN
Secondary HLSOV Power RH LED OFF
Return pins are PRIM.-HLSOV-PWR-RTN
disconnected to GND LH LED ON
except for the LH REFUEL PRIM.-HLSOV-PWR-RTN
valve commanded to close IAFS LED OFF
SEC.-HLSOV-PWR-RTN
RH LED OFF
SEC.-HLSOV-PWR-RTN
LH LED ON
SEC.-HLSOV-PWR-RTN
IAFS LED OFF
Verify 28V is applied on the HLSOV-PWR-SUP
Primary & Secondary PRIMARY LED ON
10 HLSOV Power Supply pins HLSOV-PWR-SUP
SECONDARY LED
ON
Check Primary & HLSOV-PWR-SUP PRIM. See the HLSOV
Secondary HLSOV Power TP >27.0V Power Supply
Supply Voltage HLSOV-PWR-SUP SEC. Voltage
11
TP >27.0 Measurement
Procedure (Para 2.
C. (2) (c).)
Move back LH REFUEL
HLSOV Toggle to OPEN
12 position and move AUX
REFUEL HLSOV Toggle to
CLOSE position.
Verify all the Primary & PRIM.-HLSOV-PWR-RTN
Secondary HLSOV Power RH LED OFF
Return pins are PRIM.-HLSOV-PWR-RTN
disconnected to GND LH LED OFF
except for the AUX PRIM.-HLSOV-PWR-RTN
REFUEL valve commanded IAFS LED ON
13
to close SEC.-HLSOV-PWR-RTN
RH LED OFF
SEC.-HLSOV-PWR-RTN
LH LED OFF
SEC.-HLSOV-PWR-RTN
IAFS LED ON

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Step
Step Description Expected Results Remarks

14 Verify 28V is applied on the HLSOV-PWR-SUP
Primary & Secondary PRIMARY LED ON
HLSOV Power Supply pins HLSOV-PWR-SUP
SECONDARY LED
ON
Check Primary & HLSOV-PWR-SUP PRIM. See the HLSOV
Secondary HLSOV Power TP >27.0V Power Supply
Supply Voltage HLSOV-PWR-SUP SEC. Voltage
15
TP >27.0 Measurement
Procedure (Para 2.
C. (2) (c).)
Move back AUX REFUEL
HLSOV Toggle to OPEN
16 position and move RH
REFUEL HLSOV to CLOSE
position
Verify all the Primary & PRIM.-HLSOV-PWR-RTN
Secondary HLSOV Power RH LED ON
Return pins are PRIM.-HLSOV-PWR-RTN
disconnected to GND LH LED OFF
except for the RH REFUEL PRIM.-HLSOV-PWR-RTN
valve commanded to close IAFS LED OFF
17
SEC.-HLSOV-PWR-RTN
RH LED ON
SEC.-HLSOV-PWR-RTN
LH LED OFF
SEC.-HLSOV-PWR-RTN
IAFS LED OFF

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Step
Step Description Expected Results Remarks

18 HLSOV-PWR-SUP
Verify 28V is applied on the PRIMARY LED ON
Primary & Secondary HLSOV-PWR-SUP
HLSOV Power Supply pins SECONDARY LED
ON
See the HLSOV
HLSOV-PWR-SUP PRIM. Power Supply
Check Primary &
TP >27.0V Voltage
19 Secondary HLSOV Power
HLSOV-PWR-SUP SEC. Measurement
Supply Voltage
TP >27.0 Procedure (Para 2.
C. (2) (c).)
See the FMP Shut-
Power Down the FMP
20 Down Procedure
(Para 2. C. (2) (b).)
Tab. 6

(c) If a test procedure is not successful, refer to Fig. 110 to execute the Fault
isolation procedure.

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(7) Mode Off Test


(a) Set the Test Bench for the execution of the Function testing (Refer to test
Bench set up Para.2.C. (1) (a)).
(b) Perform the test according to Tab. 7.
Step
Step Description Expected Results Remarks

1 Move AUX MODE SELECT
rotary switch in OFF
position
Move all AUX REFUEL
2
Toggles to OPEN position
Move PRESSURE Sw Nr1
3 and Nr 2 of the Test Bench
to ON position.
Set all switches of
MANAG.VALVE-POS.-IND-
4
SIG. section of TEST
BENCH to Unit position
Power Up the FMP See the FMP Start-
5 Up Procedure
(Para 2. C. (2) (a).)
After 3 ec from Power Up, FMPSTTE Health Status
Verify: section:

Mode = OFF
Management Valve = OK
Fuel Management Panel = OK

Manag. Valve PWR-SIG OFF =


LED ON
Manag. Valve PWR-SIG TRSF =
LED OFF

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Step
Step Description Expected Results Remarks

Manag. Valve PWR-SIG
REF/DEF = LED OFF
RELAY # 1 = LED OFF
RELAY # 2 = LED OFF
Power Down the FMP See the FMP Shut-
7 Down Procedure
(Para 2. C. (2) (b))
Tab. 7

(c) If a test procedure is not successful, refer to Fig. 111 to execute the Fault
isolation procedure.
(d) Set the multimeter in “BEEP” function and verify the electric connections,
refer to Fig 4 in the IPL.

NOTE: For wires test, dodge the sheath from the component pins without
removing it, as far is possible. The dodged sheath must allow the access
of the multimeter pins (Refer to Fig. 105).

(8) Mode R/D Test

(a) Set the Test Bench for the execution of the Function testing (Refer to test
Bench set up Para.2.C. (1) (a)).
(b) Perform the test according to Tab. 8.

Step
Step Description Expected Results Remarks

Move AUX MODE SELECT
1 rotary switch to REFUEL
/DEFUEL position
Move all AUX REFUEL
2
Toggles to OPEN position
Move PRESSURE Sw Nr1
3 and Nr 2 of the Test Bench
to ON position.
Set all switches of
MANAG.VALVE-POS.-IND-
4
SIG. section of TEST
BENCH to Unit position

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Step
Step Description Expected Results Remarks

5 Power Up the FMP See the FMP Start-
Up Procedure
(Para 2. C. (2) (a))
6 After 3 ec from Power Up FMPSTTE Health Status
section:

Transfer Mode = REFUEL /


DEFUEL
Management Valve = OK
Fuel Management Panel = OK

FMP Test Bench:


Manag. Valve PWR-SIG OFF =
LED OFF
Manag. Valve PWR-SIG TRSF =
LED OFF
Manag. Valve PWR-SIG
REF/DEF = LED ON
RELAY # 1 = LED OFF
RELAY # 2 = LED OFF
Power Down the FMP See the FMP Shut-
7 Down Procedure
(Para 2. C. (2) (b))
Tab. 8

(c) If a test procedure is not successful, refer to Fig. 112 to execute the Fault
isolation procedure.
(d) Set the multimeter in “BEEP” function and verify the electric connections,
refer to Fig 4 in the IPL.

NOTE: For wires test, dodge the sheath from the component pins without
removing it, as far is possible. The dodged sheath must allow the access
of the multimeter pins (Refer to Fig. 105).
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(9) Mode Manual Test

(a) Set the Test Bench for the execution of the Function testing (Refer to test
Bench set up Para.2.C. (1) (a)).
(b) Perform the test according to Tab. 9.

Step
Step Description Expected Results Remarks

1 Move AUX MODE SELECT
rotary switch to MANUAL
position
Move all AUX REFUEL
2
Toggles to OPEN position
Move PRESSURE Sw Nr1
3 and Nr 2 of the Test Bench
to ON position.
Set all switches of
MANAG.VALVE-POS.-IND-
4
SIG. section of TEST
BENCH to Unit position
Set the FWD IAFS Fuel
Quantity field of FMP STTE
main window to 2200.
5
On FWD IAFS Fuel
Quantity check box, enable
TX and disable Failure.
Set the Left Main Fuel
Quantity field of FMP STTE
main window to 2200.
6
On Left Main Fuel Quantity
check box, enable TX and
disable Failure.
Set the Right Main Fuel
Quantity field of FMP STTE
main window to 2200.
7
On Right Main Fuel
Quantity check box, enable
TX and disable Failure.

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Step
Step Description Expected Results Remarks

8 Power Up the FMP See the FMP Start-
Up Procedure (Para
2. C. (2) (a))
After 3 ec from Power Up FMPSTTE Health Status
section:

(9)
Transfer Mode = Manual
Fuel transfer = Transferring
Management Valve = OK
Fuel Management Panel = OK
Pressare SW #1 = Pressure
Pressare SW #2 = Pressure
FMP Test Bench:
Manag. Valve PWR-SIG OFF =
LED OFF
Manag. Valve PWR-SIG TRSF =
LED ON
Manag. Valve PWR-SIG
REF/DEF = LED OFF
RELAY # 1 = LED ON
RELAY # 2 = LED ON
Turn OFF the switch #1 of FMP Test Bench:
Pressure SW section of Manag. Valve PWR-SIG OFF =
LED OFF
TEST BENCH. Manag. Valve PWR-SIG TRSF =
(10) LED ON
Manag. Valve PWR-SIG
REF/DEF = LED OFF
RELAY # 1 = LED OFF
RELAY # 2 = LED ON

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Step
Step Description Expected Results Remarks

(11) After 3 sec from swith # 1 FMPSTTE Health Status
activation section:

Transfer Mode = Manual


Fuel transfer = OK
Management Valve = OK
Fuel Management Panel = OK
Pressare SW #1 = NO Pressure
Pressare SW #2 = Pressure

Turn OFF the switch #2 of FMP Test Bench:


Pressure SW section of Manag. Valve PWR-SIG OFF =
LED ON
TEST BENCH. Manag. Valve PWR-SIG TRSF =
(12) LED OFF
Manag. Valve PWR-SIG
REF/DEF = LED OFF
RELAY # 1 = LED OFF
RELAY # 2 = LED OFF
After 3 sec from switch # 2 FMPSTTE Health Status
activation section:

(13)

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Step
Step Description Expected Results Remarks

(14) Power Down the FMP See the FMP Shut-
Down Procedure
(Para 2. C. (2) (b))
Tab. 9

(c) If a test procedure is not successful, refer to Fig. 113 to execute the Fault
isolation procedure.
(d) Set the multimeter in “BEEP” function and verify the electric connections,
refer to Fig 4 in the IPL.

NOTE: For wires test, dodge the sheath from the component pins without
removing it, as far is possible. The dodged sheath must allow the access
of the multimeter pins (Refer to Fig. 105).

(10) Mode Auto Test

(a) Set the Test Bench for the execution of the Function testing (Refer to test
Bench set up Para.2.C. (1) (a)).
(b) Perform the test according to
Step
Step Description Expected Results Remarks

Move AUX MODE SELECT
(1) rotary switch to AUTO
position
Move all AUX REFUEL
(2)
Toggles to OPEN position
Move PRESSURE Sw Nr1
(3) and Nr 2 of the Test Bench
to ON position.
Set all switches of
MANAG.VALVE-POS.-IND-
(4)
SIG. section of TEST
BENCH to Unit position

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Step
Step Description Expected Results Remarks

(5) Set the FWD IAFS Fuel
Quantity field of FMP STTE
main window to 100.
On FWD IAFS Fuel
Quantity check box, enable
TX and disable Failure.
Set the Left Main Fuel
Quantity field of FMP STTE
main window to 1900.
(6)
On Left Main Fuel Quantity
check box, enable TX and
disable Failure.
Set the Right Main Fuel
Quantity field of FMP STTE
main window to 2200.
(7)
On Right Main Fuel
Quantity check box, enable
TX and disable Failure.
Power Up the FMP See the FMP Start-
(8) Up Procedure
(Para 2. C. (2) (a))

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Step
Step Description Expected Results Remarks

After 3 sec from Power Up FMPSTTE Health Status
section:

Transfer Mode = Auto


Fuel transfer = Transferring
Management Valve = OK
Fuel Management Panel = OK
LH-HLSOV Comm. =CLOSE
RH-HLSOV Comm. =CLOSE
(9) Pressare SW #1 = Pressure
Pressare SW #2 = Pressure

FMP Test Bench:


Manag. Valve PWR-SIG OFF =
LED OFF
Manag. Valve PWR-SIG TRSF =
LED ON
Manag. Valve PWR-SIG
REF/DEF = LED OFF
RELAY # 1 = LED ON
RELAY # 2 = LED ON
HLSOV-PWR-RTN RH = LEDs
OFF
HLSOV-PWR-RTN LH = LEDs
ON
HLSOV-PWR-RTN IAFS = LEDs
OFF
HLSOV-PWR-SUP Prim. = LED
ON
HLSOV-PWR-SUP Sec. = LED
ON
Set the Right Main Fuel
Quantity field of FMP STTE
main window to 2200. On
(10)
Right Main Fuel Quantity
check box, enable TX and
disable Failure.
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MAINTENANCE MANUAL
Step
Step Description Expected Results Remarks

After 3 ec from Power Up FMPSTTE Health Status
section:

FMP Test Bench:


(11) Manag. Valve PWR-SIG OFF =
LED ON
Manag. Valve PWR-SIG TRSF =
LED OFF
Manag. Valve PWR-SIG
REF/DEF = LED OFF
RELAY # 1 = LED OFF
RELAY # 2 = LED OFF
HLSOV-PWR-RTN RH = LEDs
ON
HLSOV-PWR-RTN LH = LEDs
ON
HLSOV-PWR-RTN IAFS = LEDs
ON
HLSOV-PWR-SUP Prim. = LED
OFF
HLSOV-PWR-SUP Sec. = LED
OFF

Power Up the FMP See the FMP Start-


12 Up Procedure
((Para 2. C. (2) (a))
Set the Left Main Fuel
Quantity field of FMP STTE
main window to 2200. On
(13)
Left Main Fuel Quantity
check box, enable TX and
disable Failure.

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Step
Step Description Expected Results Remarks

14 Set the Right Main Fuel
Quantity field of FMP STTE
main window to 1901. On
Right Main Fuel Quantity
check box, enable TX and
disable Failure.
Power Up the FMP See the FMP Start-
15 Up Procedure
((Para 2. C. (2) (a))
After 3 ec from Power Up FMPSTTE Health Status
section:

FMP Test Bench:


16 Manag. Valve PWR-SIG OFF =
LED OFF
Manag. Valve PWR-SIG TRSF =
LED ON
Manag. Valve PWR-SIG
REF/DEF = LED OFF
RELAY # 1 = LED ON
RELAY # 2 = LED ON
HLSOV-PWR-RTN RH = LEDs
OFF
HLSOV-PWR-RTN LH = LEDs
ON
HLSOV-PWR-RTN IAFS = LEDs
OFF
HLSOV-PWR-SUP Prim. = LED
ON
HLSOV-PWR-SUP Sec. = LED
ON

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Step
Step Description Expected Results Remarks

After 10 sec from Power Up FMPSTTE Health Status
section:

FMP Test Bench:


Manag. Valve PWR-SIG OFF =
LED OFF
Manag. Valve PWR-SIG TRSF =
LED ON
Manag. Valve PWR-SIG
REF/DEF = LED OFF
RELAY # 1 = LED ON
RELAY # 2 = LED ON
HLSOV-PWR-RTN RH = LEDs
ON
HLSOV-PWR-RTN LH = LEDs
ON
HLSOV-PWR-RTN IAFS = LEDs
ON
HLSOV-PWR-SUP Prim. = LED
OFF
HLSOV-PWR-SUP Sec. = LED
OFF

Set the Right Main Fuel


17 Quantity field of FMP STTE
main window to 2300.

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Step
Step Description Expected Results Remarks

After 3 ec from Power Up FMPSTTE Health Status
section:

Transfer Mode Auto


Fuel transfer = Transferring
Management Valve = OK
Fuel Management Panel = OK
18 LH-HLSOV Comm. =OPEN
RH-HLSOV Comm. =CLOSE
Pressare SW #1 = Pressure
Pressare SW #2 = Pressare
FMP Test Bench:
Manag. Valve PWR-SIG OFF =
LED OFF
Manag. Valve PWR-SIG TRSF =
LED ON
Manag. Valve PWR-SIG
REF/DEF = LED OFF
RELAY # 1 = LED ON
RELAY # 2 = LED ON
HLSOV-PWR-RTN RH = LEDs
ON
HLSOV-PWR-RTN LH = LEDs
OFF
HLSOV-PWR-RTN IAFS = LEDs
OFF
HLSOV-PWR-SUP Prim. = LED
ON
HLSOV-PWR-SUP Sec. = LED ON
Set the Left Main Fuel
19 Quantity field of FMP STTE
main window to 2300.

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Step
Step Description Expected Results Remarks

After 3 ec from Power Up FMPSTTE Health Status
section:

FMP Test Bench:


20
Manag. Valve PWR-SIG OFF =
LED ON
Manag. Valve PWR-SIG TRSF =
LED OFF
Manag. Valve PWR-SIG
REF/DEF = LED OFF
RELAY # 1 = LED OFF
RELAY # 2 = LED OFF
HLSOV-PWR-RTN RH = LEDs
ON
HLSOV-PWR-RTN LH = LEDs
ON
HLSOV-PWR-RTN IAFS = LEDs
ON
HLSOV-PWR-SUP Prim. = LED
OFF
HLSOV-PWR-SUP Sec. = LED OFF

Tab. 10

(c) If a test procedure is not successful, refer to flowchart 1, Fig. 114 to


execute the Fault isolation procedure.
(d) Set the multimeter in “BEEP” function and verify the electric connections,
refer to Fig 4 in the IPL.

NOTE: For wires test, dodge the sheath from the component pins without
removing it, as far is possible. The dodged sheath must allow the access
of the multimeter pins (Refer to Fig. 105)

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(11) HLSOV-PWR Short Circuit Protection Test

(a) Set the Test Bench for the execution of the Function testing (Refer to test
Bench set up Para.2.C. (1) (a)).
(b) Perform the test according to Tab. 11.

Step
Step Description Expected Results Remarks

Move AUX MODE SELECT
Rotary selector to OFF
position.
Set AUX REFUEL switches
(1)
to CLOSE position.
Set LH REFUEL and RH
REFUEL switches of UUT
to OPEN position.
Power Up the FMP See the FMP Start-
(2) Up Procedure
(Para 2. C. (2) (a))
After 1 sec from Power Up FMP Test Bench:
HLSOV-PWR-RTN RH =
LEDs OFF
HLSOV-PWR-RTN LH =
LEDs OFF
(3) HLSOV-PWR-RTN IAFS =
LEDs ON
HLSOV-PWR-SUP Prim. =
LED ON
HLSOV-PWR-SUP Sec. =
LED ON
Connect the TP socket of FMP Test Bench:
HLSOV-PWR-SUP HLSOV-PWR-RTN RH =
PRIMARY section of TEST LEDs OFF
BENCH to GND socket of HLSOV-PWR-RTN LH =
Power Supply. LEDs OFF
(4) HLSOV-PWR-RTN IAFS =
LEDs ON
HLSOV-PWR-SUP Prim. =
LED OFF
HLSOV-PWR-SUP Sec. =
LED ON
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Step
Step Description Expected Results Remarks

Connect the TP socket of FMP Test Bench:
HLSOV-PWR-SUP HLSOV-PWR-RTN RH =
SECONDARY section of LEDs OFF
TEST BENCH to GND HLSOV-PWR-RTN LH =
socket of Power Supply. LEDs OFF
(5) HLSOV-PWR-RTN IAFS =
LEDs ON
HLSOV-PWR-SUP Prim. =
LED OFF
HLSOV-PWR-SUP Sec. =
LED OFF
Turn OFF 28VDC-PWR
switch and remove the
(6) connection between both
TP and GND socket.

Power Up the FMP See the FMP Start-


(7) Up Procedure Para
2. C. (2) (a))
After 1 sec from Power Up FMP Test Bench:
HLSOV-PWR-RTN RH =
LEDs OFF
HLSOV-PWR-RTN LH =
LEDs OFF
(8) HLSOV-PWR-RTN IAFS =
LEDs ON
HLSOV-PWR-SUP Prim. =
LED ON
HLSOV-PWR-SUP Sec. =
LED ON
Tab. 11

(c) If a test procedure is not successful, refer to flowchart 1, Fig. 115 to


execute the Fault isolation procedure.
(d) Set the multimeter in “BEEP” function and verify the electric connections,
refer to Fig 4 in the IPL.

NOTE: For wires test, dodge the sheath from the component pins without
removing it, as far is possible. The dodged sheath must allow the access
of the multimeter pins (Refer to Fig. 105).

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(12) Management Valve Failure.

(a) Set the Test Bench for the execution of the Function testing (Refer to test
Bench set up Para.2.C. (1) (a)).
(b) Perform the test according to Tab. 12.

Step
Step Description Expected Results Remarks

Move AUX MODE SELECT


Rotary selector to OFF
position.
(1) Set AUX REFUEL switches
to CLOSE position.
Set LH REFUEL and RH
REFUEL switches of UUT
to OPEN position.
Set the MANAG.VALVE-
(2) POS.-IND.-SIG. “OFF”
switch in OFF Position.
Power Up the FMP See the FMP Start-
(3) Up Procedure
(Para 2. C. (2) (a))
After 3 sec from Power Up FMPSTTE Health Status
section:
Transfer Mode = OFF
(4) Fuel transfer = OK
Management Valve = FAIL

Tab. 12

(c) If a test procedure is not successful, refer to flowchart 1, Fig. 116 to


execute the Fault isolation procedure.
(d) Set the multimeter in “BEEP” function and verify the electric connections,
refer to Fig 4 in the IPL.

NOTE: For wires test, dodge the sheath from the component pins without
removing it, as far is possible. The dodged sheath must allow the access
of the multimeter pins (Refer to Fig. 105).

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(13) Verification of the FUEL MANAGEMENT PANEL (723-5345/01)

(a) Set the Test Bench for the execution of the Function testing (Refer to test
Bench set up Para 2.C.(1).) (a).
(b) Switch ON only the 5VDC Power Supply.
(c) On the T.B. put the 5VDC-LTNG switch in ON position.
(d) Verify that the panel is correctly readable and lighted.
(e) If a test procedure is not successful, refer to flowchart 1, Fig. 117 to
execute the Fault isolation procedure.
(f) If necessary, set the "Beep" function of the multimeter and verify the
electric connections, refer to Fig 4 in the IPL.

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D. Fault Isolation Flowcharts.

The Fault Isolation Procedures described by the flowcharts refers to the test
procedures previously illustrated.

In particular, the following table shows the cross-reference between Flowcharts


figures reported in the manual and test procedure of reference.

(1) Fault Isolation / Test procedures link.

Flowchart Id. Figure Refer to test procedure


Flowchart 1 Fig. 106 28Vdc POWER CONSUMPTION
Flowchart 2 Fig. 107 5Vdc PANEL POWER CONSUMPTION
Flowchart 3 Fig. 108 ARINC 429 TX TEST
Flowchart 4 Fig. 109 FMP-FCU COMMUNICATION TEST
Flowchart 5 Fig. 110 PRE-CHECK SWITCH TEST
Flowchart 6 Fig. 111 MODE OFF TEST
Flowchart 7 Fig. 112 MODE R/D TEST
Flowchart 8 Fig. 113 MODE MANUAL TEST
Flowchart 9 Fig. 114 MODE AUTO TEST
Flowchart 10 HLSOV-PWR SHORT CIRCUIT PROTECTION
Fig. 115
PANEL
Flowchart 11 Fig. 116 MANAGEMENT VALVE FAILURE
VERIFICATION OF THE FUEL MANAGEMNT
Flowchart 12 Fig. 117
PANEL 723-5345/01

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28Vdc POWER
CONSUMPTION

EXECUTE THE 28Vdc


POWER CONSUMPTION
PROCEDURE PARA 2. B. (1)

IS THE
CURRENT EXECUTE THE IS THE TEST
CONSUMPTION FUNCTIONAL PROCEDURE REPLACE U.U.T.
LOWER THAN TESTING PARA 2. C. SUCCESSFUL ?
N Y
200mA?

Y N

REPAIR
LOCATING THE
END DAMAGE REFERING TO
FUNCTIONAL TESTING
PROCEDURE PAR.2.C.

Fig. 106 28Vdc POWER CONSUMPTION (Flowchart 1)

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5Vdc PANEL
POWER CONSUMPTION

EXECUTE THE 28Vdc


POWER CONSUMPTION
PROCEDURE PARA 2. B. (2)

IS THE
CURRENT VISUAL CONTROL ARE THERE
CONSUMPTION OF THE WIRES OF RESTORE THE
BROKEN SOLDER
LOWER THAN THE FRONT PANEL SOLDER JOINTS
N JOINTS? Y
1.2A?

Y N

TEST THE WIRES OF


THE FRONT PANEL
REFER TO Fig. 104 IN
THE IPL, USING THE
MULTIMETER

REPLACE THE
ARE THE WIRES
BROKEN WIRES
DAMAGED?
Y AWG22 55550-09/089

TEST THE PANEL


CONNECTOR
P/N 67352-73M004

END

IS THE PANEL REPLACE THE


CONNECTOR PANEL CONNECTOR
DAMAGED? Y P/N 67352-73M004

REPLACE THE
FRONT PANEL
P/N 723-5345/01

Fig. 107 5Vdc PANEL POWER CONSUMPTION (Flowchart 2)

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SET THE TEST BENCH AS


SHOWN IN PARA 2. C. (1) (a) ARINC 429
TX TEST

EXECUTE THE TEST


PROCEDURE:
PARA 2.B.(4) STEP (a)-(b)

ARE THE REPLACE THE FUEL EXECUTE THE TEST


EXPECTED RESULTS CONTROL PCB
PROCEDURE:
OF THE Tab.4 ASSEMBLY
N PARA 2.B.(4) STEP (a)-(b)
VERIFIED? P/N 724-1524/01

ARE THE
END EXPECTED RESULTS END
OF THE Tab.4
VERIFIED? Y

EXECUTE THE TEST REPLACE THE FUEL


CONNECTORS PCB
PROCEDURE:
ASSEMBLY
PARA 2.B.(4) STEP (a)-(b)
P/N 724-1523/01

ARE THE
EXPECTED RESULTS
REPLACE U.U.T.
OF THE Tab.4
VERIFIED? N

END

Fig. 108 ARINC 429 TX TEST (Flowchart 3)

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SET THE TEST BENCH AS


SHOWN IN PARA 2. C. (1) (a) FMP-FCU
COMMUNICATION TEST

EXECUTE THE TEST


PROCEDURE:
PARA 2.B.(5) STEP (a)-(b)

ARE THE REPLACE THE FUEL EXECUTE THE TEST


EXPECTED RESULTS CONTROL PCB
PROCEDURE:
OF THE Tab.5 ASSEMBLY
N PARA 2.B.(5) STEP (a)-(b)
VERIFIED? P/N 724-1524/01

ARE THE
END EXPECTED RESULTS END
OF THE Tab.5
VERIFIED? Y

EXECUTE THE TEST REPLACE THE FUEL


CONNECTORS PCB
PROCEDURE:
ASSEMBLY
PARA 2.B.(5) STEP (a)-(b)
P/N 724-1523/01

ARE THE
EXPECTED RESULTS
REPLACE U.U.T.
OF THE Tab.5
VERIFIED? N

END

Fig. 109 FMP-FCU COMMUNICATION TEST (Flowchart 4)

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SET THE TEST BENCH AS


SHOWN IN PARA 2. C. (1) (a) PRE-CHECK
SWITCH TEST

EXECUTE THE TEST


PROCEDURE:
PARA 2.B.(6) STEP (a)-(b)

ARE THE REPLACE THE FUEL EXECUTE THE TEST


EXPECTED RESULTS CONTROL PCB
PROCEDURE:
OF THE Tab.6 ASSEMBLY
N PARA 2.B.(6) STEP (a)-(b)
VERIFIED? P/N 724-1524/01

ARE THE
EXPECTED RESULTS END
OF THE Tab.6
END Y
VERIFIED?

EXECUTE THE TEST REPLACE THE FUEL


CONNECTORS PCB
PROCEDURE:
ASSEMBLY
PARA 2.B.(6) STEP (a)-(b)
P/N 724-1523/01

REPLACE THE FUEL ARE THE


MANAGEMENT EXPECTED RESULTS
CABLING OF THE Tab.6
P/N 926-0642/01.01 N VERIFIED?

EXECUTE THE TEST


PROCEDURE:
PARA 2.B.(6) STEP (a)-(b)
END

ARE THE
EXPECTED RESULTS
REPLACE U.U.T.
OF THE Tab.6
VERIFIED? N

END

Fig. 110 PRE-CHECK SWITCH TEST (Flowchart 5).

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MODE OFF TEST

SET THE TEST BENCH AS


SHOWN IN PARA 2. C. (1) (a)

EXECUTE THE TEST


PROCEDURE:
PARA 2.B.(7) STEP (a)-(b)

ARE THE IN THE EXPECTED VISUAL CONTROL


RESULTS OF THE Tab. 7, ARE THERE
EXPECTED RESULTS OF THE CABLING RESTORE THE
IS ONLY THE "TRANSFER BROKEN SOLDER
OF THE Tab.7 OF THE ROTARY SOLDER JOINTS
N MODE"= NON OFF? JOINTS? Y
VERIFIED? SWITCH (SW04)
Y

Y N
N
TEST THE WIRING OF
THE SW04 USING THE
MULTIMETER, REFER
END
REPLACE THE FUEL TO Fig. 4 IN THE IPL
EXECUTE THE TEST
CONTROL PCB
PROCEDURE:
ASSEMBLY
PARA 2.B.(7) STEP (a)-(b)
P/N 724-1524/01.02

REPLACE THE
ARE THE WIRES
BROKEN WIRES
DAMAGED?
Y AWG22 55550-09/089
ARE THE
END EXPECTED RESULTS
OF THE Tab.7
Y VERIFIED? N

REPLACE THE
N
ROTARY SWITCH
(SW04) GRAYHILL
P/N 44M90-02-01-04N

EXECUTE THE TEST REPLACE THE FUEL


CONNECTORS PCB
PROCEDURE:
ASSEMBLY
PARA 2.B.(7) STEP (a)-(b)
P/N 724-1523/01

REPLACE THE FUEL ARE THE


MANAGEMENT EXPECTED RESULTS
CABLING OF THE Tab.7
P/N 926-0642/01 N VERIFIED?

EXECUTE THE TEST


PROCEDURE:
PARA 2.B.(7) STEP (a)-(b)
END

ARE THE
EXPECTED RESULTS
REPLACE U.U.T.
OF THE Tab.7
VERIFIED? N

END

Fig. 111 MODE OFF TEST (Flowchart 6).


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MODE R/D TEST

SET THE TEST BENCH AS


SHOWN IN PARA 2. C. (1) (a)

EXECUTE THE TEST


PROCEDURE:
PARA 2.B.(8) STEP (a)-(b)

IN THE EXPECTED VISUAL CONTROL


ARE THE ARE THERE
RESULTS OF THE Tab. 8, OF THE CABLING
EXPECTED RESULTS RESTORE THE
IS ONLY THE "TRANSFER OF THE ROTARY BROKEN SOLDER
OF THE Tab.8 SOLDER JOINTS
N MODE"= NON JOINTS? Y
VERIFIED? SWITCH (SW04)
REFUEL/DEFUEL? Y

Y N
N
TEST THE WIRING OF
THE SW04 USING THE
MULTIMETER, REFER
END
REPLACE THE FUEL TO Fig. 4 IN THE IPL
EXECUTE THE TEST
CONTROL PCB
PROCEDURE:
ASSEMBLY
PARA 2.B.(8) STEP (a)-(b)
P/N 724-1524/01

REPLACE THE
ARE THE WIRES
BROKEN WIRES
DAMAGED?
Y AWG22 55550-09/089
ARE THE
END EXPECTED RESULTS
OF THE Tab.8
Y VERIFIED? N

N REPLACE THE
ROTARY SWITCH
(SW04) GRAYHILL
P/N 44M90-02-01-04N

EXECUTE THE TEST REPLACE THE FUEL


CONNECTORS PCB
PROCEDURE:
ASSEMBLY
PARA 2.B.(8) STEP (a)-(b)
P/N 724-1523/01

REPLACE THE FUEL ARE THE


MANAGEMENT EXPECTED RESULTS
CABLING OF THE Tab.8
P/N 926-0642/01 N
VERIFIED?

EXECUTE THE TEST


PROCEDURE:
PARA 2.B.(8) STEP (a)-(b)
END

ARE THE
EXPECTED RESULTS
REPLACE U.U.T.
OF THE Tab.8
VERIFIED? N

END

Fig. 112 MODE R/D TEST (Flowchart 7).


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MAINTENANCE MANUAL

MODE MANUAL TEST

SET THE TEST BENCH AS


SHOWN IN PARA 2. C. (1) (a)

EXECUTE THE TEST


PROCEDURE:
PARA 2.B.(9) STEP (a)-(b)

ARE THE IN THE EXPECTED VISUAL CONTROL


RESULTS OF THE Tab. 9, OF THE CABLING ARE THERE
EXPECTED RESULTS RESTORE THE
IS ONLY THE "TRANSFER OF THE ROTARY BROKEN SOLDER
OF THE Tab.9 SOLDER JOINTS
N MODE"= NON MANUAL? SWITCH (SW04) JOINTS? Y
VERIFIED? Y

Y N
N
TEST THE WIRING OF
THE SW04 USING THE
MULTIMETER, REFER
END
REPLACE THE FUEL TO Fig. 4 IN THE IPL
EXECUTE THE TEST
CONTROL PCB
PROCEDURE:
ASSEMBLY
PARA 2.B.(9) STEP (a)-(b)
P/N 724-1524/01

REPLACE THE
ARE THE WIRES
BROKEN WIRES
DAMAGED?
Y AWG22 55550-09/089
ARE THE
END EXPECTED RESULTS
OF THE Tab.9
Y VERIFIED? N

REPLACE THE
N
ROTARY SWITCH
(SW04) GRAYHILL
P/N 44M90-02-01-04N

EXECUTE THE TEST REPLACE THE FUEL


CONNECTORS PCB
PROCEDURE:
ASSEMBLY
PARA 2.B.(9) STEP (a)-(b)
P/N 724-1523/01

REPLACE THE FUEL ARE THE


MANAGEMENT EXPECTED RESULTS
CABLING OF THE Tab.9
P/N 926-0642/01 N VERIFIED?

EXECUTE THE TEST


PROCEDURE:
PARA 2.B.(9) STEP (a)-(b)
END

ARE THE
EXPECTED RESULTS
REPLACE U.U.T.
OF THE Tab.9
VERIFIED? N

END

Fig. 113 MODE MANUAL TEST (Flowchart 8)


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MAINTENANCE MANUAL

MODE AUTO TEST

SET THE TEST BENCH AS


SHOWN IN PARA 2. C. (1) (a)

EXECUTE THE TEST


PROCEDURE:
STEP (a)-(b) PARA 2.B.(10)

ARE THE IN THE EXPECTED VISUAL CONTROL


RESULTS OF THE Tab. 10, OF THE CABLING ARE THERE
EXPECTED RESULTS RESTORE THE
IS ONLY THE "TRANSFER BROKEN SOLDER
OF THE Tab.10 OF THE ROTARY SOLDER JOINTS
N MODE"= NON AUTO? JOINTS? Y
VERIFIED? SWITCH (SW04)
Y

Y N
N
TEST THE WIRING OF
THE SW04 USING THE
MULTIMETER, REFER
END
REPLACE THE FUEL TO Fig. 4 IN THE IPL
EXECUTE THE TEST
CONTROL PCB
PROCEDURE:
ASSEMBLY
STEP (a)-(b) PARA 2.B.(10)
P/N 724-1524/01

REPLACE THE
ARE THE WIRES
BROKEN WIRES
DAMAGED?
Y AWG22 55550-09/089
ARE THE
END EXPECTED RESULTS
OF THE Tab.10
Y VERIFIED? N

N REPLACE THE
ROTARY SWITCH
(SW04) GRAYHILL
P/N 44M90-02-01-04N

EXECUTE THE TEST REPLACE THE FUEL


CONNECTORS PCB
PROCEDURE:
ASSEMBLY
STEP (a)-(b) PARA 2.B.(10)
P/N 724-1523/01

REPLACE THE FUEL ARE THE


MANAGEMENT EXPECTED RESULTS
CABLING OF THE Tab.10
P/N 926-0642/01 N VERIFIED?

EXECUTE THE TEST


PROCEDURE:
STEP (a)-(b) PARA 2.B.(10)
END

ARE THE
EXPECTED RESULTS
REPLACE U.U.T.
OF THE Tab.10
VERIFIED? N

END

Fig. 114 MODE AUTO TEST (Flowchart 9).


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MAINTENANCE MANUAL

SET THE TEST BENCH AS


SHOWN IN PARA 2. C. (1) (a) HLSOV-PWR SHORT
CIRCUIT PROTECTION PANEL

EXECUTE THE TEST


PROCEDURE:
STEP (a)-(b) PARA. 2.B.(11)

ARE THE REPLACE THE FUEL EXECUTE THE TEST


EXPECTED RESULTS CONNECTORS PCB
PROCEDURE:
OF THE Tab.11 ASSEMBLY
N STEP (a)-(b) PARA. 2.B.(11)
VERIFIED? P/N 724-1523/01

ARE THE
END
EXPECTED RESULTS END
OF THE Tab.11
VERIFIED? Y

REPLACE U.U.T.

Fig. 115 HLSOV-PWR SHORT CIRCUIT PROTECTION PANEL (Flowchart 10).

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MAINTENANCE MANUAL

SET THE TEST BENCH AS


SHOWN IN PARA 2. C. (1) (a) MANAGEMENT
VALVE FAILURE

EXECUTE THE TEST


PROCEDURE:
STEP (a)-(b) PARA. 2.B.(12)

ARE THE REPLACE THE FUEL EXECUTE THE TEST


EXPECTED RESULTS CONTROL PCB
PROCEDURE:
OF THE Tab.12 ASSEMBLY
N STEP (a)-(b) PARA. 2.B.(12)
VERIFIED? P/N 724-1524/01

ARE THE
END EXPECTED RESULTS END
OF THE Tab.12
VERIFIED? Y

EXECUTE THE TEST REPLACE THE FUEL


CONNECTORS PCB
PROCEDURE:
ASSEMBLY
STEP (a)-(b) PARA. 2.B.(12)
P/N 724-1523/01

REPLACE THE FUEL ARE THE


MANAGEMENT EXPECTED RESULTS
CABLING OF THE Tab.12
P/N 926-0642/01 N VERIFIED?

EXECUTE THE TEST


PROCEDURE:
STEP (a)-(b) PARA 2.B.(12) END

ARE THE
EXPECTED RESULTS
REPLACE U.U.T.
OF THE Tab.12
VERIFIED? N

END

Fig. 116 MANAGEMENT VALVE FAILURE (Flowchart 11).


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VERIFICATION OF THE
FUEL MANAGEMENT
PANEL 723-5345/01
SET THE TEST BENCH AS
SHOWN IN PARA 2. C. (1) (a)

EXECUTE THE TEST


PROCEDURE:
STEP (a)-(d) PARA. 2.B.(13)

IS THE
STEP (d) OF THE ARE THERE
VISUAL CONTROL OF RESTORE THE
TEST PROCEDURE BROKEN SOLDER
THE CABLING SOLDER JOINTS
SUCCESSFUL? N JOINTS? Y

Y N

DODGE THE
SHEATH WITHOUT
END
REMOVING IT

TEST THE WIRES OF


THE PANEL WITH
THE MULTIMETER
REFER TO Fig. 4 IN
THE IPL

REPLACE THE
ARE THE WIRES
BROKEN WIRES
DAMAGED?
Y AWG22 55550-09/089

REPLACE THE
AB139 HYDRAULIC
PANEL
P/N 723-5345/01

Fig. 117 VERIFICATION OF THE FUEL MANAGEMNT PANEL 723-5345/01 (Flowchart


12).

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3. Disassembly

A. General

Refer to the illustration of the IPL (Illustrated Parts List) contained in the last section
of this manual. Reference to single illustration is indicated at the beginning of each
disassembly procedure. Reference to single parts in a procedure makes use of the
item index number used in the relevant illustration.
Disassembly procedures refer only to replaceable spare parts.

CAUTION: Always use the APPLICATION ELECTROSTATIC-DISCHARGE SAFETY


PRECAUTIONS (according to EN100015/1or equivalent) NEAR
DEVICES SENSITIVE TO ELECTROSTATIC DISCHARGE. Always use
the suggested tools to perform testing procedures .Improper handling
might damage material.

NOTE: See testing and Fault Isolation to establish the completeness of the
component and detect the most probable cause of its malfunction. This is
to determine the extent of disassembly required without completely
tearing down and rebuilding the U.U.T.

B. TOOLS required

- Cross screwdriver Form H (Philips) size 1.


- 1.5 mm Allen wrench.
- 8 mm fork wrench.
- N°2, 14 mm fork wrenches.

NOTE: Equivalent TOOLS may be used with same characteristics of the ones
indicated.

C. Disassembly procedure for the FUEL MANAGEMENT PANEL (727-0860/01.01).

CAUTION: Handle the components with extreme care to avoid the wire detachment.

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(1) Disassembly the BLACK KNOB TRAPEZIUM SHAPE (921-0104/86).


(a) Refer to Fig 1 in the IPL section.
(b) By means of the 1.5 mm Allen wrench, unscrew the 2 check set screws
and remove the KNOB (refer to item 1 in figure).
(2) Disassembly the S 92 FUEL MANAGEMENT PANEL. (723-5345/01).
(a) Refer to Fig 1 in the IPL section.
(b) By means of the Ph 1 cross screwdriver, unscrew the 4 check screws and
remove the PANEL (refer to item 2 in figure).

CAUTION: Don’t scratch the surfaces of the PANEL

(3) Disassembly the FUEL PAINTED COVER (928-0883/01).


(a) Refer to Fig 1 in the IPL section.
(b) By means of the Ph 1 cross screwdriver, unscrew the 4 check screws (refer
to item 3 in figure) and remove the COVER (refer to item 6 in figure).

(4) Disassembly the FUEL CONNECTORS PCB ASSEMBLY and the FUEL
CONTROL PCB ASSEMBLY (724-1523/01 and 724-1524/01).
(a) Refer to Fig 2 in the IPL section.
(b) By means of the Ph 1 cross screwdriver, unscrew the 8 check screws (refer
to item 1 in figure) and remove the 4 TRIANGULAR STAND OFF
ASSEMBLY (refer to item 3 in figure).
(c) Disconnect the CONNECTOR (refer to item 15 in figure) from the FUEL
CONTROL PCB ASSEMBLY.
(d) By means of the Ph 1 cross screwdriver, unscrew the 4 check screws (refer
to item 5 in figure) and separate the FUEL CONTROL PCB ASSEMBLY
(refer to item 8 in figure) from the FUEL CONNECTORS PCB ASSEMBLY
(refer to item 9 in figure).
(5) Disassembly the FUEL MANAGEMENT CABLING (926-0642/01).
(a) By means of the two, 14 mm fork wrenches, unscrew the 8 check nuts and
release SW01, SW02 SW03 and SW04 (refer to item 11, 12 13 and 14 in
figure).
(b) By means of the 8 mm fork wrench unscrew PANEL CONNECTOR (refer
to item 16 i figure) and remove the FUEL MANAGEMENT CABLING (refer
to item 4 in figure) from the COUNTERPANEL (refer to item 2 in figure).

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4. Cleaning
A. Introduction.

S-92 FUEL MANAGEMENT PANEL cleaning must be performed before proceeding


to the installation on board the helicopter and before storage period.

CAUTION:

B. MATERIALS REQUIRED.
- Small size soft brush.
- Soft cloth.
- Naphtha-coal solvent: Carbosol or equivalent.
- Neutral detergent Loctite Natural Blue or equivalent.
- Compressed air.
C. Procedures:

WARNING: be careful using the naphtha coal solvent and avoid splashing. Always
wear eye protection and rubber gloves. Always wear eye protection and
rubber gloves. Use solvents/cleaning agents only in areas with a good
flow of air. Obey the manufacturer’s instructions. Put on protective
clothing. Do not drink solvents/cleaning agents. Do not smoke. Do not
breathe the gas. These materials are poisonous and flammable. Use the
approved hand and eye protection when you apply the solvents/cleaning
agents. These materials are skin irritants. If you get one of these
solvents/cleaning agents on your skin or in your eyes:

- flush it away with clean water


- get medical aid.

CAUTION: use the naphtha coal solvent with extreme care and for the cleaning only
the metallic and the painted surfaces. Avoid the contact of the naphtha
coal with: not painted plastic surfaces, rubber or electric components.

CAUTION: Always use the APPLICATION ELECTROSTATIC-DISCHARGE SAFETY


PRECAUTIONS (according to EN100015/1or equivalent) NEAR
DEVICES SENSITIVE TO ELECTROSTATIC DISCHARGE. Always use
the suggested tools to perform testing procedures .Improper handling
might damage material.
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NOTE: Equivalent materials may be used with same characteristics of the ones
indicated.

(1) Internal Cleaning.

Internal cleaning of the equipment should be performed only if an internal repair


procedure is required. Do not use detergent or chemical agents for equipment
internal cleaning.
Internal cleaning of the S-92 FUEL MANAGEMENT PANEL must be performed
as follows:

(a) Remove powder, sand and debris with a dry soft brush care to avoid
breaking the wiring and/or the component contacts.
(b) If needed, remove the dust with a stream of compressed air.

(2) External Cleaning.

External cleaning of the S-92 FUEL MANAGEMENT PANEL must be performed


as follows:

(a) Remove powder, sand and debris with a dry soft brush.
(b) Clean the only the metallic and the painted surfaces of the FMP with a soft
cloth moist with some drops of Carbosol.
(c) Clean the other surfaces (Not metallic or not painted) of the FMP with a soft
cloth moist with some drops of a Neutral detergent, remove oil and/or
grease trails.

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5. Inspection

A. Introduction.

The execution of the S-92 FUEL MANAGEMENT PANEL Inspection allow to


ascertain the serviceability of assembly.

CAUTION: Always use the APPLICATION ELECTROSTATIC-DISCHARGE SAFETY


PRECAUTIONS (according to EN100015/1or equivalent) NEAR
DEVICES SENSITIVE TO ELECTROSTATIC DISCHARGE. Always use
the suggested tools to perform testing procedures .Improper handling
might damage material.

(1) Inspection Equipment required.

The test equipment (both special and standard) required performing Inspection
activity are identified and described in the following.

(a) Special Test Equipment.


- No special test equipment required for testing and fault isolation.

(b) Standard Test Equipment.


- Callipers (any ± 1/20 mm).
- Scale (any ± 5g).

(c) TOOLS required.


- No TOOLS required for inspection.

(2) Visual check.

(a) Verify that the painted surfaces of the U.U.T. don't present scratches or any
other imperfection of painting. The U.U.T. is finished in matt black #37038
YAW FED-STD-595A. The GUARD is red #31302 YAW FED-STD-595A.
The bonding surfaces are free of paint.
(b) Disassembly the HOIST OPERATOR PANEL (Refer to Para.3.C. (3)).
(c) Verify that the PANEL is without cheeps, cracks or any other imperfections.

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(d) Verify that the IDENTIFICATION LABEL is undamaged and correctly
readable.
(e) Verify that the Replaceable Spare Parts (Refer to Para.1.C.(2)), are
undamaged, without cracks or any other imperfection. If possible check
with a visual external check without disassembly its parts.
(f) Verify that the Unit Under Test (U.U.T.) has been manufactured according
to the Outline Drawing, Fig. 3.If it is possible check with a visual external
check without disassembly its parts.
(g) Verify that the U.U.T. finishing results without cheeps, cracks or any other
imperfections.

(3) Dimensions and Weight.

(a) With the callipers, verify the dimensions of the U.U.T. respect to the Outline
Drawing Fig. 3.
(b) Using the scale, verify that the weight of the FMP is lower than 1.00 Kg.

B. Inspection Flowcharts.

The Inspection Procedures described by the flowcharts refer to the test procedures
previously illustrated.

Inspection link

Flowchart Id. Figure Refer to Inspection procedure


Flowchart 1 Fig. 501 Visual check
Flowchart 2 Fig. 502 Dimensions and Weight.

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ARE THERE
SCRATCHES OR ANY
RESTORE THE
OTHER IMPERFECTION
PAINTING
ON THE PAINTING?
Y
VISUAL CHECK

IS THE
PANEL WITHOUT REPLACE FRONT
CHEEPS CRACK OR ANY OTHER PANEL
IMPERFECTION? P/N 723-5345/01
N

IS THE ADHESIVE LABEL


REPLACE ADHESIVE
UNDAMAGED AND
LABEL P/N 920-0237/01
CORRECTLY READABLE?
N

REPLACE THE
ARE THE REPLACEABLE DAMAGED SPARAE
SPARAE PARTS DAMAGED ? PARATS
N

IS THE U.U.T.
MANUFACTURED
ACCORDING TO THE REPLACE U.U.T END
APPLICABLE
SPECIFICATION? N

IS THE
U.U.T. WITHOUT
CHEEPS CRACK OR ANY OTHER REPLACE U.U.T. END
IMPERFECTION?
N

END

Fig. 501 Visual check (Flowchart 1)

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DIMENSIONS AND WEIGHT

ARE THE
DIMENSIONS OF
THE U.U.T. IN
REPLACE U.U.T. END
ACCORDANCE
WITH THE OUTLINE
DRAWING? N

IS THE WEIGHT
LOWER THAN 1.00 Kg REPLACE U.U.T. END

END

Fig. 502 Dimensions and Weight. (Flowchart 2)

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6. Repair

NOTE: See testing and Fault Isolation to establish the completeness of the
component and detect the most probable cause of its malfunction. This is
to determine the extent of disassembly required without completely
tearing down and rebuilding the U.U.T.

This section contains the detailed description of repair procedures, consisting in the
procedures of removing and replacement of the replaceable items of the S-92 FUEL
MANAGEMENT PANEL

In case of damage at the painted surfaces of the U.U.T. these surfaces must be
restored following a specific procedure of repainting.
In this section is reported a procedure to restore the painting.

CAUTION: Always use the APPLICATION ELECTROSTATIC-DISCHARGE SAFETY


PRECAUTIONS (according to EN100015/1or equivalent) NEAR
DEVICES SENSITIVE TO ELECTROSTATIC DISCHARGE. Always use
the suggested tools to perform testing procedures .Improper handling
might damage material.

A. General

This section contains the detailed description of repair procedures, consisting in the
procedures of removing and replacement of the replaceable items of the FUEL
MANAGEMENT PANEL.
After Testing and Fault Isolation and Inspection phases, the condition of the item
(operating / failed) and most probable cause of its malfunction have been
established. This is to determine the extent of remove procedure required without
completely tear down and rebuilding the equipment.
Replacement procedures refer only to those parts that can be easily removed by
Technical Personnel with the help of standard workshop tools available at ground’s
facilities and not to those parts assembled by the Factory that have to be
considered as not replaceable and, consequently, not supplied as spare parts.
Replacement procedures refer to figures and tables reported in the last section of
this publication. Reference to single figure/table is indicated when it is of interest for
a better comprehension of procedure description.

Repair procedures refer to the illustration of the IPC (Illustrated Parts Catalogue)
contained in the last section of this manual. Reference to single illustration is
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indicated at the beginning of each assembly procedure. Reference to single parts in
a procedure makes use of the item index number used in the relevant illustration.

In case of damage of the painted surfaces of the U.U.T. these surfaces must be
restored following a specific procedure of repainting. In this section is reported a
procedure for restoring the painting.
B. List of Replacement Procedures

The remove and replace procedures of the items belong to the S-92 FMP has been
listed in the following table.
For each reported procedure, the following information are provided:

Nr Progressive number of procedure in the


table;
Description Title of the R/R procedure: it includes the
word identification of the item to be
replaced and its reference designator
(only when needed).
P/N Part Number of the item to be replaced;
Ref. Para. The number of paragraph of this section,
where the R/R procedure is described in
detail.

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Replacement Procedures List Table.

Ref.
Nr Description P/N
Para.
1 Replacement Procedure for BLACK
KNOB TRAPEZIUM SHAPE (921- 921-0104/86 C
0104/86).
2 Replacement Procedure for S-92 FUEL
723-5345/01 D
MANAGEMENT PANEL (723-5345/01).
3 Replacement Procedure for FUEL
928-0883/01 E
PAINTED COVER (928-0883/01).
4 Replacement Procedure for
920-0237/01 F
IDENTIFICATION LABEL (920-0237/01).
5 Replacement Procedure for MECH
SWITCH_V_A_1 SW01, SW02, SW03 67516-41/009 G
(67516-41/009)
6 Replacement Procedure for ROTARY
44M90-02-01-04N
SWITCH GRAYHILL, SW04 (44M90-02- H
SW04
01-04N)
7 Replacement Procedure for PANEL
COAXIAL CONNECTOR X01 (67352- 67352-73M004 I
73M004).
8 Replacement Procedure for FUEL
920-9122/01 J
MANAGEMENT GASKET (920-9122/01)
9 Replacement Procedure for FUEL
CONTROL PCB ASSEMBLY (724- 724-1524/01 K
1524/01).
10 Replacement Procedure for FUEL
CONNECTORS PCB ASSEMBLY (724- 724-1523/01 L
1523/01)
11 Replacement Procedure for FUEL
CONTROL CONNECTOR P01 222C20M11 M
(NICOMATIC 222C20M11).
12 Replacement procedure for the WIRE
55550-09/089 N
22_.38mm**2 (55550-09/089).
13 Replacement of the SPLICE (67123-
67123-03/024 O
03/024)
14 Replacement of the VANGUARD
2100-01-D50-ORA-
GASKET L410mm (2100-01-D50-ORA- P
NPS-SPL
NPS-SPL).
15 Restore the painting. N/A Q

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CAUTION: Improper handling might damage material; always use the suggested
tools to perform repair procedures.

NOTE: Equivalent TOOLS may be used with same characteristics of the ones
indicated.

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C. Replacement Procedure for BLACK KNOB TRAPEZIUM SHAPE (921-0104/86).

(1) TOOLS required.


- 1.5 mm Allen wrench.

(2) Replace BLACK KNOB TRAPEZIUM SHAPE.

(a) Refer to Fig 1 in the IPL section.


(b) Refer to the Disassembly procedure Para.3. C.
(c) Remove and replace the KNOB (refer to item 1 in figure).
(d) Assembly the U.U.T. Refer to the Assembly procedure para.7. C.

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D. Replacement Procedure for S-92 FUEL MANAGEMENT PANEL (723-5345/01).

(1) TOOLS required.


- Cross screwdriver Form H (Philips) size 1.

(2) Replace S-92 FUEL MANAGEMENT PANEL.


(a) Refer to Fig 1 in the IPL section.
(b) Refer to the Disassembly procedure para.3.C.
(c) Remove and replace the FUEL MANAGEMENT PANEL (refer to item 2 in
figure).
(d) Assembly the U.U.T. Refer to the Assembly procedure Para.7.C.

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E. Replacement Procedure for FUEL PAINTED COVER (928-0883/01).

(1) TOOLS required.


- Cross screwdriver Form H (Philips) size 1.

(2) Replace FUEL PAINTED COVER.

(a) Refer to Fig 1 in the IPL section.


(b) Refer to the Disassembly procedure para.3.C.
(c) Remove and replace the FUEL PAINTED COVER (refer to item 6 in figure).
(d) Assembly the U.U.T. Refer to the Assembly procedure Para.7.C.

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F. Replacement Procedure for IDENTIFICATION LABEL (920-0237/01).

(1) TOOLS required.


- Cutter.
- Small size brush, No specific.
- Black colour indelible pen with fine tip, No specific.
- LECHLER COATINGS, L0010497K20 ACRIPLAST INCOLORE OP.
X22474.

(2) Replace IDENTIFICATION LABEL.

WARNING: be careful using the paint and avoid splashing. Always wear eye
protection and rubber gloves. Always wear eye protection and rubber
gloves. Use solvents/cleaning agents only in areas with a good flow of air.
Obey the manufacturer’s instructions. Put on protective clothing. Do not
drink solvents/paints. Do not smoke. Do not breathe the gas. These
materials are poisonous and flammable. Use the approved hand and eye
protection when you apply the solvents/paints. These materials are skin
irritants. If you get one of these solvents/paints on your skin or in your
eyes:

- flush it away with clean water.


- get medical aid.

(a) Refer to Fig 1 in the IPL section.


(b) By means of a Cutter, remove the IDENTIFICATION LABEL (refer to item 8
in figure).
(c) Insert a new IDENTIFICATION LABEL and, using the Black colour indelible
pen, compile it as shown in .Fig.801.
(d) By means of the small size brush, Protect the IDENTIFICATION label with
the LECHLER COATINGS.

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G. Replacement Procedure for MECH SWITCH_V_A_1 SW01, SW02, SW03 (67516-


41/009)

(1) TOOLS required.


- Cross screwdriver Form H (Philips) size 1.
- Slotted screwdriver, size 2X150 mm.

(2) Replace MECH SWITCH_V_A_1.

CAUTION: Handle the components with extreme care to avoid the wire detachment.

(a) Refer to Fig 3 in the IPL section.


(b) Refer to the Disassembly procedure para.3.C.
(c) Disassembly the MECH SWITCH_V_A_1 from the COUNTERPANEL.
(d) By means of the slotted screwdriver, unscrew the 2 check screws in back
of the SWITCH, and remove the TERMINALS (refer to item 12 in figure).
(e) Remove and replace the SWITCH.
(f) By means of the slotted screwdriver fit and tighten the 2 screws in back of
the Switch and fix the TERMINALS (refer to item 12 in figure)
(g) Assembly the U.U.T. Refer to the Assembly procedure Para.7.C.

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H. Replacement Procedure for ROTARY SWITCH GRAYHILL, SW04 (44M90-02-01-


04N)

(1) TOOLS required.

- Cross screwdriver Form H (Philips) size 1.


- N°2, 14 mm fork wrenches.
- Cutter.
- Soldering iron, VSD80 WELLER or equivalent.
- SHEATH POLYOLEFIN 3mm, 58287-02/0759.
- Hot air tool, STEINELL 16055 thermo control speed or equivalent.

(2) Replace ROTARY SWITCH GRAYHILL.

CAUTION: Handle the components with extreme care to avoid the wire detachment.

(a) Disassembly the U.U.T. Refer to the Disassembly procedure Para.3.C.


(b) Refer to Fig 3 in the IPL section.
(c) By means of the cutter, remove the sheath from the pins of the ROTARY
SWITCH.
(d) By means of the soldering iron, take off the cabling from the pins of the
ROTARY SWITCH, remove and replace it (Refer to item 4 in figure).
(e) By means of the soldering iron, soldering temperature: 330 “C, connect the
cabling to the ROTARY SWITCH. For the electrical connections, refer to
Tab in Fig 4. By means of the hot air tool, protect the solder joints using the
SHEATH POLYOLEFIN 3mm.
(f) Assembly the U.U.T. Refer to the Assembly procedure Para.7.C.

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I. Replacement Procedure for PANEL COAXIAL CONNECTOR X01 (67352-73M004).

(1) TOOLS required.


- Cross screwdriver Form H (Philips) size 1.
- 1.5 mm Allen wrench.
- 8 mm fork wrench.
- Cutter.
- Soldering iron, VSD80 WELLER or equivalent.
- SHEATH POLYOLEFIN 3mm, 58287-02/0759.
- Hot air tool STEINELL, 16055 thermo control speed or equivalent.

(2) Replace PANEL COAXIAL CONNECTOR.

CAUTION: Handle the components with extreme care to avoid the wire detachment.

(a) Disassembly the U.U.T. Refer to the Disassembly procedure Para.3.C.


(b) Refer to Fig 3 in the IPL section.
(c) By means of the cutter, remove the sheath from the pins of the
CONNECTOR.
(d) By means of the soldering iron, soldering temperature: 330 “C, take off the
cabling from the pins of the ROTARY SWITCH, remove and replace it
(Refer to item 4 in figure).
(e) By means of the soldering iron connect the cabling to the CONNECTOR.
For the electrical connections, refer to Tab in Fig 4.
(f) By means of the hot air tool, protect the solder joints using the SHEATH
POLYOLEFIN 3mm.
(g) Assembly the U.U.T. Refer to the Assembly procedure Para.7.C.

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J. Replacement Procedure for FUEL MANAGEMENT GASKET (920-9122/01)

(1) TOOLS required.

- Cross screwdriver Form H (Philips) size 1.


- Cutter.
- Silicone adhesive, 57510-06/004.

(2) Replace FUEL MANAGEMENT GASKET.

CAUTION: Handle the components with extreme care to avoid the wire detachment.

(a) Disassembly the U.U.T. Refer to the Disassembly procedure Para.3.C.


(b) Remove the necessary components. Refer to the relative procedure of this
section.
(c) Refer to Fig 1 in the IPL section.
(d) By means of the cutter, remove the GASKET (refer to item 10 in figure).
(e) Insert a new GASKET and fix it using silicone adhesive..
(f) Assembly the U.U.T. Refer to the Assembly procedure Para.7.C.

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K. Replacement Procedure for FUEL CONTROL PCB ASSEMBLY (724-1524/01).

(1) TOOLS required.


- Cross screwdriver Form H (Philips) size 1.
- 1.5 mm Allen wrench.
- 8 mm fork wrench.
- N°2, 14 mm fork wrenches.

(2) Replace FUEL CONTROL PCB ASSEMBLY.

CAUTION: Handle the components with extreme care to avoid the wire detachment.

(a) Disassembly the U.U.T. Refer to the Disassembly procedure Para.3.C.


(b) Remove the necessary components. Refer to the relative procedure of this
section.
(c) Refer to Fig 2 in the IPL section.
(d) Remove and replace the FUEL CONTROL PCB ASSEMBLY (refer to item
8 in figure).
(e) Assembly the U.U.T. Refer to the Assembly procedure Para.7.C..

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L. Replacement Procedure for FUEL CONNECTORS PCB ASSEMBLY (724-1523/01)

(1) TOOLS required.

- Cross screwdriver Form H (Philips) size 1.


- 1.5 mm Allen wrench.
- 8 mm fork wrench.
- N°2, 14 mm fork wrenches.

(2) Replace FUEL CONNECTORS PCB ASSEMBLY.

CAUTION: Handle the components with extreme care to avoid the wire detachment.

(a) Disassembly the U.U.T. Refer to the Disassembly procedure Para.3.C.


(b) Remove the necessary components. Refer to the relative procedure of this
section.
(c) Refer to Fig 2 in the IPL section.
(d) Remove and replace the FUEL CONNECTORS PCB ASSEMBLY (refer to
item 9 in figure).
(e) Assembly the U.U.T. Refer to the Assembly procedure Para.7.C..

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M. Replacement Procedure for FUEL CONTROL CONNECTOR P01 (NICOMATIC


222C20M11).

(1) TOOLS required.

- Cross screwdriver Form H (Philips) size 1.


- 1.5 mm Allen wrench.
- 8 mm fork wrench.
- N°2, 14 mm fork wrenches.
- Cutter.
- Pin Insertion/removal tool, (Nicomatic C12935 or equivalent).
- Crimp tool, M22520/2-01 with Positioner (Nicomatic C12929 or
equivalent).
- MALE PIN CONNECTOR (Nicomatic C13064-P).
- Silicone adhesive, 57510-06/004.

(2) Replace FUEL CONTROL CONNECTOR.

CAUTION: Handle the components with extreme care to avoid the wire detachment.

(a) Disassembly the U.U.T. Refer to the Disassembly procedure Para.3.C.


(b) Remove the necessary component. Refer to the relative procedure of this
section.
(c) Refer to Fig 3 in the IPL section.
(d) By means of the cutter, remove the cabling of the CONNECTOR (refer to
item 5 in figure) remove and replace it..
(e) By means of the crimp tool M22520/2-01, crimp a new MALE PINS
CONNECTOR (refer to item 7 in figure) to the WIRE.
(f) By means of the insertion/removal tool C12935, insert the relative pin into
the CONNECTOR. For the electric connections, refer to Fig 4 in the IPL.
(g) Protect the insertions of the MALE PINS CONNECTOR using the silicone
adhesive.
(h) Assembly the U.U.T. Refer to the Assembly procedure Para.7.C..

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N. Replacement procedure for the WIRE 22_.38mm**2 (55550-09/089).

(1) TOOLS required.

- Cross screwdriver Form H (Philips) size 1.


- 1.5 mm Allen wrench.
- 8 mm fork wrench.
- N°2, 14 mm fork wrenches.
- Cutter.
- Soldering iron, VSD80 WELLER or equivalent.
- Pin Insertion/removal tool, (Nicomatic C12935 or equivalent).
- Crimp tool, M22520/2-01 with Positioner (Nicomatic C12929 or
equivalent).
- MALE PIN CONNECTOR (Nicomatic C13064-P).
- Silicone adhesive, 57510-06/004.
- Slotted screwdriver, size 2X150 mm.
- Terminal, 67211-61/001.
- CABLE ACC__m**2, 67173-01/002.
- Hot air tool STEINELL, 16055 thermo control speed or equivalent.

CAUTION: Handle the components with extreme care to avoid the wire detachment.

(2) Replace WIRE 22_.38mm**2 connected to SW01, SW02 and SW03..


(a) Disassembly the U.U.T. Refer to the Disassembly procedure Para.3.C.
(b) Remove the necessary components. Refer to the relative procedure of this
section.
(c) Refer to Fig 3 in the IPL section.
(d) Locate the damaged WIRE.
(e) By means of the cutter, trim the CABLE ACC__m**2 (refer to item 10 in
figure) and loosen the damaged WIRE.
(f) By means of the slotted screwdriver, unscrew the necessary screw behind
the SWITCH and loosen the TERMINAL (refer to item 11 in figure).
(g) By means of the insertion/removal tool M81969/14-10, remove the MALE
PIN CONNECTOR from the P01 CONNECTOR.
(h) Remove and replace the damaged WIRE.
(i) Crimp a new TERMINAL at the extremity of the WIRE.
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(j) By means of the crimp tool M22520/2-01, crimp the MALE PIN
CONNECTOR at the other extremity of the WIRE.
(k) By means of the insertion/removal tool M81969/14-10, insert the MALE PIN
CONNECTOR into the P01 CONNECTOR. For the electric connections,
refer to Fig 4 in the IPL.
(l) By means of the slotted screwdriver, fit and tighten the screw behind the
SWITCH and fix the TERMINAL of the wire to the SWITCH.
(m) Pick up the cabling using the CABLE ACC__m**2.
(n) Protect the insertions of the MALE PINS CONNECTOR using the silicone
adhesive.
(o) Assembly the U.U.T. Refer to the Assembly procedure Para.7.C.

(3) Replace WIRE 22_.38mm**2 connected to SW04 and X01.


(a) Disassembly the U.U.T. Refer to the Disassembly procedure Para.3.C.
(b) Remove the necessary components. Refer to the relative procedure of this
section.
(c) Refer to Fig 3 in the IPL section.
(d) Locate the damaged WIRE.
(e) By means of the cutter, trim the CABLE ACC__m**2 (refer to item 10 in
figure) and loosen the damaged WIRE.
(f) By means of the cutter, cut off the SHEATH from the pin of damaged
WIRE.
(g) By means of the soldering iron, soldering temperature: 330 “C, take off the
damaged WIRE from the relative component.
(h) By means of the insertion/removal tool M81969/14-10, remove the MALE
PIN CONNECTOR from the P01 CONNECTOR.
(i) Remove and replace the damaged WIRE.
(j) By means of the crimp tool M22520/2-01, crimp the MALE PIN
CONNECTOR at the other extremity of the WIRE.
(k) By means of the insertion/removal tool M81969/14-10, insert the MALE PIN
CONNECTOR into the P01 CONNECTOR. For the electric connections,
refer to Fig 4 in the IPL.
(l) Protect the insertions of the MALE PINS CONNECTOR using the silicone
adhesive.

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(m) By means of the soldering iron, connect the WIRE to the relative
component and protect the solder joint using the SHEATH POLYOLEFIN
(refer to item 11 in figure)
(n) Pick up the cabling using the CABLE ACC__m**2.
(o) Assembly the U.U.T. Refer to the Assembly procedure Para.7.C.

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O. Replacement of the SPLICE (67123-03/024)

(1) TOOLS required.

- Cross screwdriver Form H (Philips) size 1.


- 1.5 mm Allen wrench.
- 8 mm fork wrench.
- N°2, 14 mm fork wrenches.
- Cutter.
- Hot air tool, STEINELL 16055 thermo control speed or equivalent.

CAUTION: Handle the components with extreme care to avoid the wire detachment.

(2) Replace the SPLICE.


(a) Disassembly the U.U.T. Refer to the Disassembly procedure Para.3.C.
(b) Remove the necessary components. Refer to the relative procedure of this
section.
(c) Refer to Fig 3 in the IPL section.
(d) By means of the cutter, trim the cabling, remove and replace the damaged
SPLICE.
(e) By means of the hot air tool, assembly the new SPLICE to the cabling. For
the electric connections, refer to Fig 4 in the IPL..
(f) Assembly the U.U.T. Refer to the Assembly procedure Para.7.C.

P. Replacement of the VANGUARD GASKET L410mm (2100-01-D50-ORA-NPS-SPL).

(1) TOOLS required.

- Cross screwdriver Form H (Philips) size 1.


- 1.5 mm Allen wrench.
- 8 mm fork wrench.
- N°2, 14 mm fork wrenches.
- Cutter.
- Silicone adhesive, 57510-06/004.

(2) Replace FUEL MANAGEMENT GASKET.


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(a) Disassembly the U.U.T. Refer to the Disassembly procedure Para.3.C.


(b) Remove the necessary components. Refer to the relative procedure of this
section.
(c) Refer to Fig 1 in the IPL section.
(d) By means of the cutter, remove the GASKET (refer to item 16 in figure).
(e) Insert a new GASKET and fix it using silicone adhesive..
(f) Assembly the U.U.T. Refer to the Assembly procedure Para.7.C.

Q. Restore the painting.

(1) TOOLS required.

- Polyurethane paint, colour: matt black #37038 I.A.W. FED-STD-595A.


- Small size brush.

(2) Restore the painting.

WARNING: be careful using the paint and avoid splashing. Always wear eye
protection and rubber gloves. Always wear eye protection and rubber
gloves. Use solvents/cleaning agents only in areas with a good flow of air.
Obey the manufacturer’s instructions. Put on protective clothing. Do not
drink solvents/paints. Do not smoke. Do not breathe the gas. These
materials are poisonous and flammable. Use the approved hand and eye
protection when you apply the solvents/paints. These materials are skin
irritants. If you get one of these solvents/paints on your skin or in your
eyes:

- flush it away with clean water.


- get medical aid.

CAUTION: Care that the paint doesn’t cover the legend on the FRONT PANEL or on
the IDENTIFICATION LABELS. Don’t paint the bonding surfaces.

(a) By means of the small size brush, eliminate every leaking or scratch from
the painted surfaces.

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7. Assembly

A. General
Assembling of the equipment parts must be performed after maintenance
operations like internal cleaning or when a component must be replaced.
Assembly must be performed following, in the reverse sequence, the disassembly
procedures.

Assembly procedures refer to the illustration of the IPL (Illustrated Parts List)
contained in the last section of this manual. Reference to single illustration is
indicated at the beginning of each assembly procedure. Reference to single parts in
a procedure makes use of the item index number used in the relevant illustration.

Assembly procedures refer only to replaceable spare parts.

CAUTION: Always use the APPLICATION ELECTROSTATIC-DISCHARGE SAFETY


PRECAUTIONS (according to EN100015/1or equivalent) NEAR
DEVICES SENSITIVE TO ELECTROSTATIC DISCHARGE. Always use
the suggested tools to perform testing procedures .Improper handling
might damage material.

B. TOOLS required.

- Cross screwdriver Form H (Philips) size 1.


- 1.5 mm Allen wrench.
- 8 mm fork wrench.
- N°2, 14 mm fork wrenches.
- Loctite . 57510-04/012.
- Silicone adhesive . 57510-11/002.

NOTE: Equivalent materials may be used with same characteristics of the ones
indicated.

C. Assembly procedure for the S-92 FUEL MANAGEMENT PANEL (727-0860/01.01).

CAUTION: Handle the components with extreme care to avoid the wire detachment.

(1) Assembly the FUEL MANAGEMENT CABLING (926-0642/01).

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Refer to Fig 2 in the IPL section.
(a) By means of the 8mm fork wrench, fit and tighten the PANEL
CONNECTOR (refer to item 16 i figure).
(b) By means of the 2, 14mm fork wrenches, fit and tighten the 8 check nuts
and fix the SW01, SW02 SW03 and SW04 (refer to item 11, 12 13 and 14
in figure) to the COUNTERPANEL (refer to item 2 in figure).
(2) Assembly the FUEL CONNECTORS PCB ASSEMBLY and the FUEL CONTROL
PCB ASSEMBLY (724-1523/01 and 724-1524/01).
(a) Refer to Fig 2 in the IPL section.

NOTE: handle the 2 PCB ASSEMBLYES (item 8 and 9 in figure) with care to
avoid breaking the pins of the connectors.

(b) Assembly the FUEL CONTROL PCB ASSEMBLY (refer to item 8 in figure)
to the FUEL CONNECTORS PCB ASSEMBLY (refer to item 9 in figure).
(c) By means of the Ph 1 cross screwdriver, fit and tighten the 4 check screws
(refer to item 5 in figure) previously plunged in the loctite and fix the FUEL
CONTROL PCB ASSEMBLY (refer to item 8 in figure).
(d) Connect the CONNECTOR (refer to item 15 in figure) the connector of the
FUEL CONTROL PCB ASSEMBLY.
(e) By means of the Ph 1 cross screwdriver fit and tighten the 8 check screws
(refer to item 1 in figure) an fix the 4 TRIANGULAR STAND OFF
ASSEMBLY (refer to item 3 in figure).

NOTE: Assembly the 4 STAND OFF as shown in SEC. A-A.

(3) Assembly the FUEL PAINTED COVER (928-0883/01).


(a) Refer to in the IPL section.
(b) By means of the Ph 1 cross screwdriver, fit and tighten the 4 check screws
(refer to item 3 in figure) and fix the cover (refer to item 6 in figure).
(4) Assembly the S 92 FUEL MANAGEMENT PANEL. (723-5345/01).
(a) Refer to Fig 1 in the IPL section.
(b) By means of the Ph 1 cross screwdriver, fit and tighten the 4 check screws
and fix the PANEL (refer to item 2 in figure).
(5) Assembly the BLACK KNOB TRAPEZIUM SHAPE (921-0104/86).
(a) Refer to in the IPL section.
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(b) By means of the 1.5 mm Allen wrench, fit and tighten the 2 set screws,
previously plunged in the silicone adhesive and fix the KNOB (refer to item
1 in figure).
(6) Final check
(a) After the assembly procedure verify the correct working of the U.U.T.
(b) Refer to para 2.B and 2.C for testing procedures (refer to).
(c) If a test fails, refer to the fault insulation flowcharts (refer to para 2.D) to
locate the damage. Repair the damaged parts referring to the Procedures
given in para 6.
(d) If test procedures are successful the U.U.T. has to be considered repaired.

PARA TEST DESCRIPTION SPECIFIED MEASURED VALUES


VALUES
- PHYSICAL INSPECTION
5.A.(1) Identification & Marking Pass/Fail
5.A.(2) Visual check Pass/Fail
5.A.(3).(a) Dimension Check Pass/Fail
5.A.(4).(b) Weight < 1.00 Kg
- ELECTRICAL TEST
2.B.(1) 28 Vdc Power Consumption < 200 mA
5 Vdc Panel power
2.B.(2) < 1.2 A
consumption
- FUNCTIONAL TEST
2.C.(4) ARINC429 TX TEST Pass/Fail
2.C.(5) FMP-FCU Communication Pass/Fail
Test
2.C.(6) Pre-Check Switch Test Pass/Fail
2.C.(7) Mode Off Test Pass/Fail
2.C.(8) Mode R/D Test Pass/Fail
2.C.(9) Mode Manual Test Pass/Fail
2.C.(10) Mode Auto Test Pass/Fail
2.C.(11) HLSOV Short Circuit
Pass/Fail
Protection test
2.C.(12) Management Valve Failure Pass/Fail

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D. Storage (Including transportation).

NOTE: Equivalent substitutes may be used for listed items

(1) Fixtures, tools, test and support equipment.


N°2 Protective caps: SOURIAU 70206 or equivalents.
Antistatic envelop: No specific.
Not-reusable carton Container: No specific.
Label, No specific.

(2) CONSUMABLE MATERIALS


Adhesive tape: No specific-
(3) Procedure
(a) Packing

NOTE: Always put the U.U.T. in its original package.

- Install the two protective caps on the rear connector.


- Put the U.U.T in antistatic envelope.
- Put the U.U.T. (in its antistatic envelope) in a container
- Seal the container with adhesive tape.
- Bond an identification label on the envelope, which shows (refer to
Fig.801):
the vendor name (SIRIO PANEL-FIRENZE)
The Sirio Panel Part Number.
The Serial Number.
The unity designation.
The Agusta Part Number.

(b) Storage
- For storage, pack the U.U.T. in its original package or equivalent as
specified in Para (a)
- Store the packed U.U.T. in clean, dry, well ventilated conditions with no
corrosive fumes.

The ground temperature range is from –55 °C to +85 °C.


The relative humidity range is lower than 95%

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(c) Shipping
- For transport, pack the U.U.T. in its original package or equivalent as
specified in Para (a).

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PAGE INTENTIONALLY LEFT BLANK

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8. Fits and Clearances

(1) This chapter provides fit and clearance criteria as well as torque values in the
U.U.T.
For the assembly of the threaded elements refer to Tab. 13 Tab. 14 Tab. 15 and
Tab. 16 that showings the torque max applicable to nuts and screws.

INOX STEEL SCREW BOLTED TO INOX STEEL FEMALE


THREAD
M 2 2,5 3
C (Nm) 0,35 0,45 0,7

Tab. 13

- INOX STEEL SCREW BOLTED TO ALUMINIUM


- INOX STEEL SCREW BOLTED TO WIRE INSERT
- INOX STEEL SCREW WITH NOT METALLIC PART
INTERPOSED
M 2 2,5 3
C (Nm) 0.14 0.23 0.45

Tab. 14

- INOX STEEL SCREW BOLTED TO NOT METALLIC PART


- INOX STEEL SCREW WITH PCB INTERPOSED
M 2 2,5 3
C (Nm) 0.1 0.2 0.3

Tab. 15

PANEL MOUNTING COMPONENTS

P/N SW01 SW02- SW03 SW04


C (Nm) 1.7 1.7 1.7 1.7

Tab. 16

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(2) Dimensions of the S-92 FUEL MANAGEMENT PNAEL.


The dimensions of the S-92 FUEL MANAGEMENT PANEL P/N 727-0860/01.01, are shown
in Fig.801.

FUEL MANAGEMENT PANEL


AUX REFUEL
OPEN
LH REFUEL RH REFUEL
OPEN OPEN
CLOSE

CLOSE CLOSE

AUX MODE SELECT


AUTO

J01 J02
REFUEL/DEFUEL OFF

MANUAL

SIRIO PANEL - A4582


P/N 727-0860/01
S/N Date

P/N 508618

Fig.801 S-92 FUEL MANAGEMENT PANEL 727-0860/01.01

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9. Special Tools, Fixtures and Equipment

No special Tools or Fixtures are required to assembly, disassembly or, in general,


to perform maintenance action on the FMP.
The test equipment required performing testing and fault isolation activities are
identified and described in the following. Test Box 728-0225/01
Equivalent substitutes may be used for listed items.

NOTE: Equivalent materials may be used with same characteristics of the ones
indicated.

A. Test equipment

The FMP Test Box 728-0225/01 is composed by:


FMP Test Bench Cable.
FMP Arinc 429 Cable.

(a) The Test Box is an interconnection tool to facilitate the user o measure
and/or drive FMP discrete and communicate to FMP Arinc 429 data bus..
Fig.901 shows the front panel of the Test Box.

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FUNCTIONAL TEST ARINC TOOL

J2 J1A ARINC
J23
429

INSULATION TEST CASE 28VDC-PWR 5VDC-LTNG


J19 J21 J8 J14
J22 J20A
J3 J10

28VDC-PWR PRIMARY SECONDARY MANAG. VALVE- MANAG. VALVE- G-FAIL


ON SW12 ON HLSOV-PWR-RTN PWR-SIG. POS.-IND.-SIG. ON
HLSOV-PWR-RTN
ON SW2
ON

D2
ON
D8
ON OFF OFF OFF D16
D12 D1 UNIT
PWR-CONS.
J4
-RH- -RH-
ON SW4
ON
J5 TRSFR TRSFR OFF
ON ON D3 UNIT
D4 D9
5VDC-LTNG -LH- -LH- ON SW5
ON SW14 ON ON
REF
REF/DEF OFF
D5
DEF UNIT
ON ON
D6 D11
D15
PWR-CONS. -IAFS- -IAFS- RELAY PRESSURE SW
J11

J12 ON ON
SW7
HLSOV-PWR-SUP #1
ARINC 429 #1
ON TP D7
P N D13
J7
TX PRIMARY ON ON
J18 SW9
J17 J6
#2 #2
P N REFS D10
ON
RX D14
J9
J13
J16 J15 SECONDARY
TP FMP TEST-BOX
SIRIO PANEL P.N.

B
D

Fig.901 Test Box 728-0225/01

(b) Test Box Dimensions (ref to Fig.901) and Weight:

-A (mm): 310
-B (mm): 170
-C (mm): 85
-D (mm) 49
-Weight (kg) 1.160+/-10%

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10. Illustrated Parts List

A. Introduction

(1) Purpose of the illustrated parts list.


The illustrated Parts List is provided to enable the identification and ordering of
approved parts required for the repair of the S-92 P/N 727-0860/01.01

(2) Use of Illustrated Parts List.

Each page of the Illustrated Parts List is set out in six columns:

(a) Figure and Item number column. The figure number refers to the illustration
on which a part may be identified. The appropriate figure number is shown
on each page at the top of the column. The item number against each part
used to identify that part on the appropriate illustration.
(b) Part Number column.
(c) Airline Stock Number Column. This column is left blank for airline stock
number.
(d) Nomenclature column. This column contains the item name for each part, a
description and a Vendor’s code where applicable.
(e) Effectively Column. This column contains an uppercase alphanumeric
character (A, B, C) to identify interchange ability relationships between
items in the same figure. In our own case this column is left blank.
(f) Units per assembly.

B. Equipment Designator Index.


NOT APPLICABLE.

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C. Numerical Index –

UNITS
AIRLINE STOCK
PART NUMBER FIG. ITEM PER
Nr.
ASSY
921-0104/86 1 1 1
723-5345/01 1 2 1
61530-27/036 1 3 4
61170-06/124 1 4 4
61170-03/128 1 5 4
928-0883/01 1 6 1
920-9122/01 1 7 1
920-0237/01 1 8 1
61550-33/005 2 1 8
921-2166/01 2 2 1
921-2179/01 2 3 4
926-0642/01 2 4 1
61530-27/005 2 5 4
61170-06/123 2 6 4
61170-03/127 2 7 4
724-1524/01 2 8 1
724-1523/01 2 9 1
2100-01-D50-
2 10 1
ORA-NPS-SPL
11
2 12
13
67516-41/009 3
1
3 2
3
GRAYHILL 2 14
1
44M90-02-01-04N 3 4
NICOMATIC 2 15
1
222C20M11 3 5
2 16
67352-73M004 1
3 6
NICOMATIC
3 7 20
C13064-P
67123-03/024 3 8 2

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UNITS
AIRLINE STOCK
PART NUMBER FIG. ITEM PER
Nr.
ASSY
55550-09/089 3 9 -
67173-01/002 3 10 7

Illustrated Parts Catalogue – S-92 FUEL MANAGEMENT PANEL 727-0860/01.01

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3
4
5
8
6

2
1

Fig 1 Exploded view (Part 1)

FIG. PART NUMBER AIRLINE NOMENCLATURE EFFECT. UNITS


STOCK PER
ITEM Nr. ASSY
BLACK KNOB
1- 1 921-0104/86 1
TRAPEZIUM SHAPE
FUEL
2 723-5345/01 MANAGEMENT S92 1
PANEL
INOX SCREW
3 61530-27/036 4
M3X8mm
INOX ELASTIC
4 61170-06/124 4
WASHER M3-6.2mm

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FIG. PART NUMBER AIRLINE NOMENCLATURE EFFECT. UNITS


STOCK PER
ITEM Nr. ASSY
INOX FLAT
5 61170-03/128 4
WASHER M3-6mm
FUEL PAINTED
6 928-0883/01 1
COVER
FUEL
7 920-9122/01 MANAGEMENT 1
GASKET
IDENTIFICATION
8 920-0237/01 1
LABEL

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1
9
3
8
7
6
5
4
12
11
10
2
1

15
13

14
16

Fig 2 Exploded view (Part 2).

FIG. PART AIRLINE NOMENCLATURE EFFECT. UNITS


NUMBER STOCK PER
ITEM Nr. ASSY
INOX SCREW
2- 1 61550-33/005 8
M3X6mm
FUEL MANAGEMENT
2 921-2166/01 COUNTERPANEL 1
ASSEMBLY
TRIANGULAR STAND
3 921-2179/01 4
OFF ASSEMBLY

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FUEL MANAGEMENT
4 926-0642/01 1
CABLING
INOX SCREW
5 61530-27/005 4
M2.5X6mm
INOX ELASTIC
6 61170-06/123 4
WASHER M2.5-5.1mm
INOX FLAT WASHER
7 61170-03/127 4
M2.5-5mm
FUEL CONTROL PCB
8 724-1524/01 1
ASSEMBLY
FUEL CONNECTORS
9 724-1523/01 1
PCB ASSEMBLY
2100-01-D50- VANGUARD GASKET
10 1
ORA-NPS-SPL L410mm
MECH SWITCH_V_A_1
11 67516-41/009
(SW01)
MECH SWITCH_V_A_1
12 67516-41/009 3
(SW02)
MECH SWITCH_V_A_1
13 67516-41/009
(SWO3)
GRAYHILL ROTARY SWITCH
14 44M90-02-01- (SW04) 1
04N
NICOMATIC FUEL CONTROL
15 1
222C20M11 CONNECTOR
PANEL COAXIAL
16 67352-73M004 1
CONNECTOR

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7
10
8

1 12

11
9
4

Fig 3 Cabling assembly.

FIG. PART AIRLINE NOMENCLATURE EFFECT. UNITS


NUMBER STOCK PER
ITEM Nr. ASSY
MECH SWITCH_V_A_1
3- 1 67516-41/009
(SW01)
MECH SWITCH_V_A_1
2 67516-41/009 3
(SW02)
MECH SWITCH_V_A_1
3 67516-41/009
(SWO3)
GRAYHILL ROTARY SWITCH
4 44M90-02-01- (SW04) 1
04N
NICOMATIC FUEL CONTROL
5 1
222C20M11 CONNECTOR

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PANEL COAXIAL
6 67352-73M004 1
CONNECTOR
NICOMATIC
7 CONNECTOR PIN 20
C13064-P
8 67123-03/024 SPLICE 2
9 55550-09/089 WIRE 22_.38mm**2 -
10 67173-01/002 CABLE ACC__m**2 7

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Fig 4-electric connections

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Fig 5 Schematics Diagrams 724-1523/01 Sheet 1

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Fig 6 Schematics Diagrams 724-1523/01 Sheet 2

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Fig 7 Schematics Diagrams 724-1523/01 Sheet 3

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Fig 8 Schematics Diagrams 724-1523/01 Sheet 4

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Fig 9 Schematics Diagrams 724-1523/01 Sheet 5

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Fig 10 Schematics Diagrams 724-1524/01 Sheet 1

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Fig 11 Schematics Diagrams 724-1524/01 Sheet 2

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Fig 12 Schematics Diagrams 724-1524/01 Sheet 3

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Fig 13 Schematics Diagrams 724-1524/01 Sheet 4

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Fig 14 Schematics Diagrams 724-1524/01 Sheet 5

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Fig 15 Schematics Diagrams 724-1524/01 Sheet 6

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Fig 16 Schematics Diagrams 724-1524/01 Sheet 7

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