RSA-5 & RSA-10AD1 Fuel Injection Systems Operation & Service Manual * OPERATION * INSTALLATION * ADJUSTMENT * SERVICE =PRECIEGIGN AIRMOTIVE CORPORATION FORM 15-338, NOV 8, 1996 3220 100th Street S.W. #E, Everett, WA 98204 USAPRECISION AIRMOTIVE CORPORATION FUEL INJECTION SYSTEMS OPERATION AND SERVICE MANUAL. MODEL RSA-5 AND RSA-10AD1 LIST OF EFFECTIVE PAG! Insert latest changed pages; dispose of superseded pages in accordance with applicable regulations, NOTE: On a changed page, the portion of the text affected by the latest change is indicated by a vertical line, or other change symbol, in the page number margin of the page. RECORD OF CHANGES Total number of pages in this manual is 35, consisting of the following: Page Issue Date Title Novi96 List of Effective Pages.......... Now/96 i 7 Nov/96 i Now/96 -Novi/96 -Nov/96 -Nov/96 -Nov/96 (ov/96 Nov/96 iv . v Blank 101-109 110 Blank... M1 201-203 Novi96 301-304 Nov/96 401-402 Novi96 501-503 -Nov/96 601 Nov/96 701-702 801-805... Nov/96 Nov/96 15-338E 11/8/961 1 MI Vv PRECISION AIRMOTIVE CORPORATION FUEL INJECTION SYSTEMS OPERATION AND SERVICE MANUAL MODEL RSA-5 AND RSA-10AD1 TABLE OF CONTENTS INTRODUCTION... DESCRIPTION AND PRINCIPLES OF OPERATION. ..sneess 101 General... General Description Airflow Section... Regulator Section. Fuel Metering Section. Flow Divider Air Bleed Nozzles. ‘Automatic Mixture Control Unit Manual Leaning Schemati INSTALLATION... Mounting Unit on Engine . Mounting Flow Divider...... Installation of Naturally Aspirated Air Bleed Nozzles. Installation of Turbocharged Air Bleed Nozzles Fuel Line Connection and Installation... Metered Fuel Line. Installation of Nozzle Line TROUBLESHOOTING CHART. SERVICE NOTES General. Starting... Idling. Shutdown (Cut-off) Automatic Mixture Control FIELD ADJUSTMENTS. Starting Procedures Idle Speed and Mixture Adjustment 15-338E 11/8/96PRECISION AIRMOTIVE CORPORATION FUEL INJECTION SYSTEMS OPERATION AND SERVICE MANUAL MODEL RSA-5 AND RSA-10AD1 TABLE OF CONTENTS, VI FUEL SYSTEM REQUIREMENTS. Fuel Pressure.. Fuel Contamination VII INJECTION SYSTEM NOTES, GROUND AND FLIGHT. Induction System Icing Vaporization Icing VIIl_ MAINTENANCE, LUBRICATION AND PREPARATION FOR STORAGE. Maintenance Lubrication Preparation for Storage 15-338E 11/8/9615-338E PRECISION AIRMOTIVE CORPORATION FUEL INJECTION SYSTEMS, OPERATION AND SERVICE MANUAL MODEL RSA-5 AND RSA-10AD1 INTRODUCTION ‘This operation and service manual has been prepared and distributed by Precision Airmotive Corporation, and is intended for use by personnel responsible for the installation, adjustment, and maintenance of Fuel Injection Systems. Periodic revisions to this manual will be made to incorporate the latest operation and maintenance procedures. If, in the opinion of the reader, any information or procedures have been omitted or require clarification, please direct your comments and suggestions to the above office. An endeavor will be made to include such information in future revisions, NOTE If operation, installation, and maintenance procedures in this manual conflict with those specified in the applicable airframe and/or engine manual, the procedures in the airframe and/or engine manual shall apply. 11/8/96 iii15-338E PRECISION AIRMOTIVE CORPORATION FUEL INJECTION SYSTEMS. OPERATION AND SERVICE MANUAL MODEL RSA-5 AND RSA-10AD1 NOTE For application information, refer to Precision Airmotive publication “Fuel Metering Certification List”, Form Number 15-769 or the Aircraft-type certificate Data Sheet. 11/8/96 ivPRECISION AIRMOTIVE CORPORATION FUEL INJECTION SYSTEMS: OPERATION AND SERVICE MANUAL MODEL RSA-5 AND RSA-10AD1 DESCRIPTION AND PRINCIPLES OF OPERATION GENERAL Ll. AI RSA type fuel injection systems are based on the principle of measuring engine air ‘consumption by use of a venturi tube and using the airflow forces to control fuel flow to the engine. Fuel distribution to the individual cylinders is obtained by the use of a fuel flow divider and air bleed nozzles with the exception of some helicopter installations that use an engine manufacturer furnished fitting, GENERAL DESCRIPTION 1-2. The following is a description of the operation of the injection system. AIRFLOW SECTION 1-3. A measure of the airflow consumption of the engine is accomplished by sensing impact pressure and venturi throat pressure in the throttle body. ‘These pressures are vented to the two sides of the air diaphragm. (In the case of the RSA-SABI, these two pressures are connected by an air channel in which the AMC unit is located). By movement of the throttle valve, a change in engine air consumption occurs that will change the velocity of the air in the venturi; this will reflect an immediate change in the air differential pressure. The air pressure is the engine manifold pressure. REGULATOR SECTION 1-4, The regulator system consists of a fuel diaphragm which opposes the force of the air diaphragm; this force is transmitted through a regulator stem., The fuel pressure shown on the ball side of the fuel diaphragm is the pressure after the fuel has passed through the fuel strainer, the manual mixture control rotary plate, the main metering jet and rotary idle plate, and is transferred to as metered fuel pressure. Fuel inlet pressure is applied to the opposite side of the fuel diaphragm. Since three of the four pressures involved in the regulator (namely, impact air, venturi throat, and inlet fuel pressure) are fixed, the fourth pressure (metered fuel pressure) must vary to keep the regulator in balance. This is accomplished by the ball valve controlling the orifice opening 15-338E, 11/8/96 101PRECISION AIRMOTIVE CORPORATION FUEL INJECTION SYSTEMS OPERATION AND SERVICE MANUAL, MODEL RSA-5 AND RSA-10AD1 DESCRIPTION AND PRINCIPLES OF OPERATION Figure I RSA-SADI External View 1-5. Since the air differential pressure is a function of the volumetric airflow, and the fuel differential pressure is a function of the fuel flow, a consistent fuel-to-air ratio is always maintained with this system, regardless of the quantity of air being consumed by the engine. 1-6. Consideration has been made for the low air forces experienced in the idle range by the incorporation of the constant head idle spring. This spring provides a constant fuel differential pressure that will allow adequate fuel supply for the idle range. As the air forces increase, the spring compresses until the spring retainer touches the air diaphragm and acts as a solid member. 15-338E, 11/8/96 102PRECISION AIRMOTIVE CORPORATION FUEL INJECTION SYSTEMS OPERATION AND SERVICE MANUAL. MODEL RSA-5 AND RSA-10AD1 DESCRIPTION AND PRINCIPLES OF OPERATION Figure 2. RSA-SABI External View FUEL METERING SECTION 17. 1-8. 1-9. This section incorporates an inlet fuel strainer, a manual mixture control valve, and an idle valve. The idle valve is connected to the throttle valve by means of an external adjustable link, The ‘main metering jet is incorporated in the passage between inlet fuel pressure and metered fuel pressure. In some cases (according to the parts list requirement) an enrichment jet is also located between these pressures. The enrichment jet fuel channel is also uncovered by the idle valve at a pre-determined point to provide additional fuel enrichment in the power range. ‘The manual mixture control valve produces a full rich condition when the lever is against the rich stop, and a progressively leaner mixture as the lever is moved toward idle cut-off. Both idle speed (closed throttle position) and idle mixture (relationship between throttle position and idle valve position) may be readily adjusted externally to meet individual engine requirements. 15-338E 11/8/96 103PRECISION AIRMOTIVE CORPORATION FUEL INJECTION SYSTEMS OPERATION AND SERVICE MANUAL MODEL RSA-5 AND RSA-10AD1 DESCRIPTION AND PRINCIPLES OF OPERATION Figure 3. RSA-10AD1 External View The fuel metering section of the RSA-SAD2 also incorporates a take-off adjustment valve. This valve should be adjusted in accordance with the engine manufacturers instructions. This will allow the fuel flows on twin engine aircraft to be matched within approximately + 1% from engine to engine. FLOW DIVIDER 1. The metered fuel is delivered from the fuel control unit to a pressurized flow divider. This unit keeps metered fuel under pressure, divides fuel to the various cylinders at idle and off idle, and shuts off the individual nozzle lines when the control is placed in I.C.O. Referring to the schematic diagram, metered fuel pressure enters the flow divider through a channel that permits fuel to pass through the I.D. of the flow divider valve, AC idle the fuel pressure from the regulator must build up to overcome the spring force applied to the diaphragm and valve assembly. This moves the valve upward until fuel can pass out through the O.D. annulus of the valve to the fuel nozzle. Since the regulator meters and delivers a fixed amount of fuel to the flow divider, the valve will only open as far as necessary to pass this amount to the nozzles. At idle the opening required is very small, and the nozzle discharge pressure is negligible, thus the fuel is divided for the individual eylinders at this point by the flow divider. As fuel flow through the regulator is increased above idle requirements, fuel pressure builds up in the nozzle lines, fully opens the flow divider valve, and fuel distribution to the engine becomes a function of the discharge nozzles. 15-338E 11/8/96 104PRECISION AIRMOTIVE CORPORATION FUEL INJECTION SYSTEMS OPERATION AND SERVICE MANUAL MODEL RSA-5 AND RSA-10AD1 DESCRIPTION AND PRINCIPLES OF OPERATION LA-3204 La3110| Figure 4. Flow Divider - Four, Figure 5. Shrouded Nozzle Six or Eight Cylinder Outlet 2524370 Key to Figure 5A Spring Holder Spring Spring Holder raed Packing Tube Asseably Preformed Packing Body Assenbly Shipping Cep Figure 5A. Airbleed Nozzle Assembly 2524866 (Replaces Shrouded Nozzle 2524370) 15-338E, 11/8/96 105PRECISION AIRMOTIVE CORPORATION FUEL INJECTION SYSTEMS OPERATION AND SERVICE MANUAL MODEL RSA-5 AND RSA-10AD1 DESCRIPTION AND PRINCIPLES OF OPERATION Key to Figure 58 Spring Holder Spring 1 2 3. Threaded Spring Holder i. ae A LA-8249 Figure 5B. Airbleed Nozzle Assembly 2524917 Key to Figore 64 1. Body Assembly 2) Shipping Cap LA3UIIA| LA-8250 Figure 6. Nozzle Assembly 2524107 Figure 6A. Airbleed Nozzle Assembly 2524864 15-338E, 11/8/96 106PRECISION AIRMOTIVE CORPORATION FUEL INJECTION SYSTEMS. OPERATION AND SERVICE MANUAL MODEL RSA-5 AND RSA-10AD1 DESCRIPTION AND PRINCIPLES OF OPERATION | LA-3112A| Figure 7. Shrouded Nozzle 2524369 AIR BLEED NOZZLES The fuel discharge nozzles for the individual cylinders are of the air bleed configuration. Each nozzle incorporates a calibrated jet, the size of which is determined by; 1) fuel inlet pressure available, and 2) the maximum fuel flow required by the engine. All nozzles are calibrated to flow alike (within + 2%) and are interchangeable between engines and cylinders, ‘The fuel is discharged through the fuel jet into a fuel/air chamber located between the fuel jet and the fueV/air jet. This mixture of fuel and air is then expelled into the intake manifold. Fuel pressure, before the individual nozzles, is in direct proportion to fuel flow; therefore, a simple pressure gage can be calibrated in fuel flow, gallons per hour, and be employed as a flowmeter. Engines modified with turbo-superchargers must use shrouded nozzles. By use of an air manifold these nozzles are vented to the injector air inlet pressure. 15-338E 11/8/96 107PRECISION AIRMOTIVE CORPORATION FUEL INJECTION SYSTEMS OPERATION AND SERVICE MANUAL. MODEL RSA-5 AND RSA-10AD1 DESCRIPTION AND PRINCIPLES OF OPERATION 3. Spring older 4. Preformed Packing 5. Tube Assembly 6 5 reformed Packing Body Asseably Shipping Cep \ Wy ~ Figure 7A. Airbleed Nozzle Assembly 2524865 AUTOMATIC MIXTURE CONTROL UNIT 1-15 Air flow into an engine is normally referred to as pounds per hour. Asa rule of thumb, the ‘engine consumes six pounds of air per brake horse power regardless of altitude. A volumetric air flow metering unit will enrich approximately 1.7 to 2.3 percent for every one thousand feet in altitude, This enrichment variation depends on the specific altitude. Variations are greater at the higher altitudes. 1-16. The direct reason for the enrichment is the change in air density. IFaltitude or temperature is increased it will require a greater air volume to flow the same weight of air into the engine. This will increase the air metering forces and in turn inerease the fuel metering forces resulting in a richer fuel/air mixture as altitude increases. 1-17, To automatically correct for this natural enrichment at altitude an automatic mixture control assembly is incorporated in the RSA-SAB1 fuel injector. ‘The automatic mixture control works independently of, and in parallel with, the manual mixture control. It provides a variable orifice between the two air chambers (impact pressure and venturi throat pressure) to regulate the air metering forces. 15-338E 11/8/96 108PRECISION AIRMOTIVE CORPORATION FUEL INJECTION SYSTEMS OPERATION AND SERVICE MANUAL MODEL RSA-5 AND RSA-10AD1 DESCRIPTION AND PRINCIPLES OF OPERATION ‘The mixture control assembly consists of a contoured needle that is moved in and out of an orifice by a bellows assembly. This bellows assembly is sensitive to changes in air pressure and temperature. At ground level, the needle attached to the bellows is positioned to restrict the orifice and a large differential pressure between impact pressure and venture suction sides of the air diaphragm. When the aircraft increases altitude, the bellows elongates and moves the needle further into the orifice due to the change in air density. The reverse taper of the needle increases the orifice opening and bleeds air from the impact pressure side of the air diaphragm to the venturi suction side. This reduces the differential pressure and in turn reduces the fuel flow. The needle is contoured such that regardless of altitude (or air density) the correct differential pressure (impact to venturi suction) is established across the air diaphragm in the regulator for any specific air flow to the engine, MANUAL LEANING 1-19. 1-20, The setting incorporated in the injector satisfies the engine requirements for sea level operation. As air density decreases (altitude) the throttle is opened to maintain the same power. Opening the throttle causes a higher air metering force which, in tur, results in a greater fuel flow. ‘The manual mixture control may then be moved towards the cut-off position to reduce fuel flow to the desired value. ¢ the automatic mixture control unit compensates for altitude enrichment in the RSA-SABL injector, manual leaning to cruise power fuel flow is the only adjustment needed. 15-338E 11/8/96 10915-338E PRECISION AIRMOTIVE CORPORATION FUEL INJECTION SYSTEMS OPERATION AND SERVICE MANUAL MODEL RSA-5 AND RSA-10AD1 THIS PAGE LEFT BLANK INTENTIONALLY. 11/8/96 11096/8/11 ZHAI peeeees ¥'s"n o7ggy PueTPET susgshs uoza9efur Tang TavOT-VSY PUR ‘Ta¥S-¥SE Ww ASQ atv 38N1 LOvAWI ANaWLsnray BUNLXIW 3701 83A37 BATA 3700 (399) MO74 Jans ¥H/S87 HO BuNSSB¥d 31ZZON LNaWLsnedy 033¢S 370) ¥BA37 S7LLONHL BATVA STLLONHL NIT 1331S SS3INIVLS HONI 8/1 (749 ¥3¢ 3NO) 31ZZ0N 73Ns ‘puag yanog - uofaerodzog xrpuag eu - + “9961 ‘£961 ‘C96T ‘196T oIuByz4dog “Tayé-S¥ 81#poK yo wwadeya opaeueyos BVA TIVv8 WOVEHAVIO TNS Tease sly ONINS Kooaaa ANVLSNOO ONISdS 37GI QVAH LNVLSNOD ¥3AR7 440-1N9 3701 GNY TO¥LNOD BYNLXIW TWANDW agee-st BYNLXIN LYWOLNY 39VANIT Y3A37 STLLOeHL OL G3L9aNNO9 ¥3A31 BATA 3701. WW -NoiLo3s LFN 13Ng——! uaNiveLs 73N4 NOLLVEZ40 dO SSTSIONTYA ONY NOTLET¥OSEa ONINBLEWPRECISION AIRMOTIVE CORPORATION FUEL INJECTION SYSTEMS OPERATION AND SERVICE MANUAL MODEL RSA-5 AND RSA-10AD1 INSTALLATION MOUNTING UNIT ON ENGINE 2-1. The injector can be mounted on the engine intake manifold inlet flange at any attitude to facilitate engine to air frame combination installation, taking into consideration that the throttle linkage and manual mixture control linkage must be attached to the unit. 2-2, Anallowance should be made for adequate ventilation to the injector because of possible high ambient temperatures within the engine nacelle. MOUNTING FLOW DIVIDER 2-3. ‘The flow divider can be mounted at an optimum location with a predetermined bracket configuration, however, it must be mounted with the nozzle line fittings in a horizontal plane. INSTALLATION OF NATURALLY ASPIRATED AIR BLEED NOZZLES (Refer to Figures 5, 5A, and SB.) 2-4, Install nozzle in cylinder using a clean, deep well 1/2 inch socket wrench. Tighten and torque nozzle to 60 Ibs-inches. Refer to manufacturer's maintenance manual for “A” alignment. NOTE Do not remove shipping cap from nozzle until nozzle is installed 2-5. Remove shipping cap and connect fuel line to nozzle. Tighten fuel line union nut (AN-805-2) to a torque value of 25-50 Ibs-inches. It is also permissible to tighten fuel line union nut finger tight and then continue tightening nut with a wrench - 30° to 60° (1/2 to 1 flat of unit). Torque in excess of 50 Ilbs-inches may result in damage to the parts. INSTALLATION OF TURBOCHARGED AIR BLEED NOZZLES (Refer to Figures 6, 6, 7 and 7A). 2-6. Install nozzle in cylinder using a clean, deep well 1/2-inch socket wrench. Tighten and torque nozzle to 60 Ibs-inches. Refer to manufacturer's maintenance manual for “A” alignment. 15-338E 11/8/96 201