AVSTAR LFR-NNSS5 Installation, Operation & Maintenance Manual

Fuel system

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Fuel System Installation, Operation

& Maintenance Manual

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Principal Manual)

Models LFR-NNSS5, LFR-NMLH10, LFR-NNLH10,

LFR-NNLS10, LFR-NNSH10 & LFR-NNSM10 Servo Fuel

Injectors with Air Bleed Injection Nozzles & Flow Divider

May 27, 2022

Part No. AFS-IOM-02

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Page 1 Fuel System Installation, Operation & Maintenance Manual Principal Manual) Models LFR-NNSS5, LFR-NMLH10, LFR-NNLH10, LFR-NNLS10, LFR-NNSH10 & LFR-NNSM10 Servo Fuel Injectors with Air Bleed Injection Nozzles & Flow Divider May 27, 2022 Part No. AFS-IOM-02 AVStar Fuel Systems. All Rights Reserved.
Page 2 1365 Park Lane South Jupiter, FL 33458 USA Phone: U.S. and Canada Toll Free: +1 (866) 982-7287 Factory Direct: +1 (561) 575-1560 AVStar’s regular business hours are Monday through Friday from 8:00AM through 5:00PM Eastern Time (-5 GMT). Visit us Online: avstardirect.com...
Page 3: Record Of Revisions
AFS-IOM-02 RECORD OF REVISIONS Revision Revised Revision Date Revision Description Original 5/27/2022 CES Original Release of Manual - Part No. AFS-IOM-02 AVStar Fuel Systems. All Rights Reserved Record of Revisions May 27, 2022 Page i...
Page 5: Service Document List
AVStar Air Bleed Nozzles Overhaul Manual FSM FD AVStar Fuel Flow Divider Overhaul Manual AVStar AFS-SB6 Fracture of a Fuel Diaphragm stud in Fuel Servos Adjustment of Servo Regulators fitted with AVStar AVStar AFS-SB9 Diaphragms AVStar AFS-SB10 Fuel Servos Installed in an Updraft Configuration...
Page 6 Lycoming Approves the Use of Safety Cable Lycoming S.L. L114 Engine and Accessory Maintenance Publications Lycoming S.L. L247 Shelf Life Requirements Lycoming S.L. L253 Warranty repair of AVStar Fuel System Lycoming S.L. L279 Lycoming Model Designation for Fuel Injectors Lycoming SSP-110 Certificated Aircraft Engines Lycoming SSP-112...
Page 8: Table Of Contents
— Cleaning Guidelines ........................ 13 — Fuel Inlet Strainer........................14 — Injection Nozzle Cleaning ....................... 15 Unscheduled Corrective Maintenance ................ 05-50 — Incorrect Fuel or Fuel Contamination ..................17 Table of Contents AVStar Fuel Systems. All Rights Reserved Page vi May 27, 2022...
Page 9 — Throttle & Altitude Mixture Control ..................38 Appendix A ........................— Servo Fuel Injector Fuel Pressure Limitations ..............40 — Servo Fuel Injector Model LFR-NNSS5 Features ..............41 — Model LFR-NNSS5 Identification of Features ..............42 — Servo Fuel Injector Model LFR-NNSH10 Features .............. 43 —...
Page 10 — Servo Fuel Injector Model LFR-NNSM10 Features ............. 47 — Model LFR-NNSM10 Identification of Features ..............48 — Air Bleed Injection Nozzle Features ..................49 — Flow Divider (Fuel Manifold) Features ................. 50 Table of Contents AVStar Fuel Systems. All Rights Reserved Page viii May 27, 2022...
Page 12: List Of Figures
AFS-IOM-02 LIST OF FIGURES Fig. No. Figure Title Page Injection Nozzle Flow Check Model LFR-NNSS5 Identification of Features Model LFR-NNSH10 Identification of Features Model LFR-NMLH10, NNLH10, NNLS10 Identification of Features Model LFR-NNSM10 Identification of Features Air Bleed Injection Nozzle Features...
Page 14: List Of Tables
AFS-IOM-02 LIST OF TABLES Table No. Table Title Page Part Number Applicability xviii Fuel Strainer O-Ring Identification Fault Isolation Guide (Troubleshooting) List of Tables AVStar Fuel Systems. All Rights Reserved Page xii May 27, 2022...
Page 16: Abbreviations And Acronyms
Installation, Operation and Maintenance Manual Illustrated Parts Catalog Pound Methyl-Ethyl-Ketone AFS-OM: AVStar Overhaul Manual Part Number Pounds per square inch Service Bulletin Service Instruction Service Letter Time Between Overhaul Abbreviations and Acronyms AVStar Fuel Systems. All Rights Reserved Page xiv May 27, 2022...
Page 18: Introduction
Airframer. The AVStar fuel injection system is based on the principle of measuring air flow using the air flow signal in a stem type regulator to convert the air force into a fuel force. This fuel force when applied across the fuel metering section makes fuel flow proportional to air flow.
Page 19 (which is above ambient) will blow the fuel in the nozzle air chamber through the vent and into the engine nacelle. The table on the following page identifies the applicable Part Numbers covered by this manual. AVStar Fuel Systems. All Rights Reserved Introduction May 27, 2022...
Page 20 AV2576562-4 AV2576642-1 AV2581800 AV2581500 LFR-NNSM10 AFS-IPC-07 FSM LFR-NNSM10 AV2582100 AV2524864-2 AV2524917-1 AIR BLEED AFS-IPC-08 FSM ABN NOZZLES AV2524923-1 AV2524926-1 AV2524232-2 AV2576526-1 FLOW DIVIDER AFS-IPC-09 FSM FD AV2576564-1 AV2576624-1 Introduction AVStar Fuel Systems. All Rights Reserved Page xviii May 27, 2022...
Page 21 Refer to any of the latest revisions of the applicable AVStar Service Document List for additional service instructions, as well as any service documents issued by AVStar showing a date after the issue date or current revision date of this manual.
Page 22 As advancements in technological applications on this fuel system continue, AVStar will make future revisions to this manual. However, if more timely distribution is necessary, AVStar posts all pertinent documents to our website under ‘Product Support’. Here you can find all active Service Bulletins (AFS-SB), Installation Operation &...
Page 23 Copyright This publication is a copyrighted work. All rights reserved by AVStar Fuel Systems. Content in this manual cannot be changed or released as a reprint, electronic media output, or web communiqué without written permission from AVStar Fuel Systems.
Page 24 AVStar’s regular business hours are Monday through Friday from 8:00 A.M. through 5:00 P.M. Eastern Time (-5 GMT) Change of Address Notification The owner of the manual is responsible for supplying a change of address to AVStar Fuel Systems. Introduction AVStar Fuel Systems. All Rights Reserved...
Page 26: Airworthiness Limitations
14 CFR §§ 43.16 and 91.403 of the Federal Aviation Regulations (FAR) unless an alternative program has been FAA-approved. 2. Currently there are no Airworthiness Limitations issued. Airworthiness Limitations AVStar Fuel Systems. All Rights Reserved Page xxiv May 27, 2022...
Page 29: General
NOTICE: The fuel system could require an overhaul or replacement before TBO. A. The TBO for all AVStar Servo Fuel Injectors, Flow Dividers, and Air Bleed Injection Nozzles carrying valid return to service documentation is the same as the TBO identified by the manufacturer of the engine for which it is specified.
Page 30: Maintenance Practices
B. DO NOT reuse any gasket. You must install a new gasket. C. It is considered best practice to replace any o-ring which has been removed. D. Be advised the opening of any fuel system voids all applicable AVStar warranties. AVStar cannot restrict certified repairman from performing any repairs, assuming the latest revisions of the proper manuals are followed.
Page 32: Time Limits / Inspections
NOTICE: Inspections in this manual apply to the fuel system and not the engine or aircraft. Refer to the applicable manufacturer’s maintenance manual for inspection information on all other components. 05-10 AVStar Fuel Systems. All Rights Reserved Page | 4 May 27, 2022...
Page 34: Scheduled Maintenance Checks
(6) While unlikely, examine the exterior of the fuel injector for cracks and any surface damage. NOTICE: If you find any cracks contact AVStar immediately. 05-20 AVStar Fuel Systems. All Rights Reserved Page | 6...
Page 35 Before flight, make sure that all leaks and problems have been corrected or repaired. (13) Complete all other required inspections in accordance with the Engine or Airframe manufacturer’s instructions prior to installing the cowling on the aircraft. AVStar Fuel Systems. All Rights Reserved 05-20 May 27, 2022 Page | 7...
Page 36 CORRECT ALL LEAKS. IF FUEL LEAKS ARE NOT CORRECTED BEFORE FLIGHT, THE ENGINE CAN HAVE LOSS OF POWER OR ENGINE FAILURE CAN OCCUR. 05-20 AVStar Fuel Systems. All Rights Reserved Page | 8 May 27, 2022...
Page 37 CORRECT ALL LEAKS. IF FUEL LEAKS ARE NOT CORRECTED BEFORE FLIGHT, THE ENGINE CAN HAVE LOSS OF POWER OR ENGINE FAILURE CAN OCCUR. AVStar Fuel Systems. All Rights Reserved 05-20 May 27, 2022 Page | 9...
Page 38 CORRECT ALL LEAKS. IF FUEL LEAKS ARE NOT CORRECTED BEFORE FLIGHT, THE ENGINE CAN HAVE LOSS OF POWER OR ENGINE FAILURE CAN OCCUR. 05-20 AVStar Fuel Systems. All Rights Reserved Page | 10 May 27, 2022...
Page 39 CORRECT ALL LEAKS. IF FUEL LEAKS ARE NOT CORRECTED BEFORE FLIGHT, THE ENGINE CAN HAVE LOSS OF POWER OR ENGINE FAILURE CAN OCCUR. AVStar Fuel Systems. All Rights Reserved 05-20 May 27, 2022 Page | 11...
Page 41: Cleaning
NOTICE: Disassembly of the fuel system or any modification made by a party other than AVStar Fuel Systems or one of its approved Service Centers voids all applicable warranties. Refer to the AVStar website for a list of all currently authorized Service Centers.
Page 42: Fuel Inlet Strainer
If the Fuel Inlet Strainer cannot be thoroughly cleaned or if there is any damage to it, the strainer should be replaced. F. Refer to AVStar Service Information Letter AFS-SIL-02 for additional details. G. Once the fuel inlet strainer has been cleaned and dried, install a new O-ring onto the strainer.
Page 43: Injection Nozzle Cleaning
100 hours operation time. The entire injection nozzle assembly is recommended to be removed annually to prevent the possibility of seizure within the engine cylinder. AVStar Fuel Systems. All Rights Reserved 05-30 May 27, 2022...
Page 45: Unscheduled Corrective Maintenance
(c) AVStar recommends returning the applicable components to our facility or one of our service centers for detailed evaluation to determine if repair or overhaul is necessary.
Page 46: Volcanic Ash/Particulate Contamination
ABNORMAL PERFORMANCE OR OPERATION ARE WITNESSED, FOD WITHIN ANY OF THE INTERNAL CIRCUITS WITHIN THE FUEL SYSTEM SUBSEQUENTLY BECOME DISLODGED AFFECT PERFORMANCE. (2) The fuel system requires replacement or complete overhaul. 05-50 AVStar Fuel Systems. All Rights Reserved Page | 18 May 27, 2022...
Page 48: Unscheduled Servicing
Low Fuel Pressure Adjust fuel pressure if applicable. Check fuel Engine Maint. pump and drive and/or replace fuel pump or fuel Manual pressure regulator. Continued on Next Page 12-30 AVStar Fuel Systems. All Rights Reserved Page | 20 May 27, 2022...
Page 49 Nozzle Cleaning” Throttle lever out of Adjust in accordance with the airframe Airframe Maint. adjustment manufacturer's instructions. Adjust lever for full Manual travel. Continued on Next Page AVStar Fuel Systems. All Rights Reserved 12-30 May 27, 2022 Page | 21...
Page 50 2. Remove, inspect and clean as required fuel inlet Manual strainer (see 05-30) Engine surges Cause not typically See Engine Manual Engine Maint. associated with the fuel Manual system. Continued on Next Page 12-30 AVStar Fuel Systems. All Rights Reserved Page | 22 May 27, 2022...
Page 51 Engine Maint. exhaust gaskets as necessary. Manual Linkage between Readjust as described in Engine Maintenance Engine Maint. wastegate and fuel Manual Manual system out of adjustment (when applicable) AVStar Fuel Systems. All Rights Reserved 12-30 May 27, 2022 Page | 23...
Page 53: Air Intake
AFS-IOM-02 71-60 – AIR INTAKE 1. Refer to the applicable section of the Aircraft Maintenance Manual for Airbox and Carburetor Heat/Alternate Air connection details and maintenance. AVStar Fuel Systems. All Rights Reserved 71-60 May 27, 2022 Page | 25...
Page 55: Engine
I. If the idle speed setting is not stable after repeated attempts, complete a check of the idle linkage. Look for loose connections which could cause erratic idling. J. AVStar DOES NOT recommend re-indexing or taking apart the idle linkage clevis assembly. Idle fuel flows are initially set when tested on a qualified test bench, with specific throttle positions and fuel flows.
Page 57: Engine Fuel System
NOT be reinstalled as they are not applicable to the parts list of the fuel injector. This includes but is not limited to additional inlet fittings or adapters, pressure fittings, and airframe outlet fittings. AVStar has no authorization to deem these components airworthy or qualified for return to service.
Page 58: Servo Fuel Injector Installation Preparation Requirements & De-Preserving
30 days or more. If not certain as to the status of the fuel injector being installed and if it has been preserved, AVStar recommends the following procedure as a best practice, best performed with the fuel injector removed from the engine: (1) Remove the fuel inlet and strainer and clean the strainer in accordance with Chapter 05-30 of this manual.
Page 59: Servo Fuel Injector Installation
“Full-Rich” position and the throttle fully open. Rotate the fuel injector so that gravity allows the fuel to drain from the outlet (facing down) and rotate the servo front to back and side to side. AVStar Fuel Systems. All Rights Reserved 73-10 May 27, 2022...
Page 60 B. This procedure should be followed anytime the fuel injector is anticipated to be inactive for 30 days or more. C. Repeat the process annually when in storage for more than one year. 73-10 AVStar Fuel Systems. All Rights Reserved Page | 32 May 27, 2022...
Page 61: Injection Nozzle Replacement
NOTICE: If multiple injection nozzles are to be removed, apply a label to each fuel line and injection nozzle for reference on assembly. AVStar recommends installing a shipping cap over the nozzle once the fuel line is disconnected. This will secure the nozzle insert within the nozzle body and prevent the introduction of FOD during the removal and installation.
Page 62: Injection Nozzle Fuel Flow Check
If cleaning does not correct the scattered stream, replace the injection nozzle. Fuel injection nozzles are not repairable. J. Disconnect the fuel line from the injection nozzle. K. Lubricate an acceptable injection nozzle threads with engine oil mixture. 73-10 AVStar Fuel Systems. All Rights Reserved Page | 34 May 27, 2022...
Page 63: Flow Divider Replacement
(4) Attach all fuel fittings with the fuel injector line to the corresponding identified ports on the flow divider. Torque the fuel line union nuts to between 35 to 50 in- lbs. AVStar Fuel Systems. All Rights Reserved 73-10 May 27, 2022...
Page 64: Flow Divider Storage & Preservation
Pack the wrapped unit in a suitable shipping case B. Repeat the process annually when in storage for more than one year. 73-10 AVStar Fuel Systems. All Rights Reserved Page | 36 May 27, 2022...
Page 66: Power Control
AFS-IOM-02 76-10 – ENGINE POWER CONTROL 1. Refer to the applicable section of the Aircraft Maintenance Manual for Throttle and Altitude Mixture Control connection details and maintenance. 76-10 AVStar Fuel Systems. All Rights Reserved Page | 38 May 27, 2022...
Page 68: Servo Fuel Injector Fuel Pressure Limitations
B. The airframe installation may specify additional fuel pressure requirements, especially those which make use of return lines from the servo. AVStar encourages all operators to adhere to the requirements set forth by both the engine manufacturer and airframe where the fuel injection servo is installed.
Page 69 (6) *The plug next to the primary fuel outlet should be inspected for any signs of a fuel leak or stain around the plug. (7) *The impact tubes should be inspected for fuel which would indicate a leaking regulator seal. AVStar Fuel Systems. All Rights Reserved APPENDIX A May 27, 2022 Page | 41...
Page 71 (6) *The plug next to the data plate should be inspected for any signs of a fuel leak or stain around the plug. (7) *The impact tubes should be inspected for fuel which would indicate a leaking regulator seal. AVStar Fuel Systems. All Rights Reserved APPENDIX A May 27, 2022 Page | 43...
Page 73 (6) *The plug next to the alternate fuel outlet port should be inspected for any signs of a fuel leak or stain. (7) *The plug next to the AVStar logo should be inspected for any signs of a fuel leak or stain around the plug.
Page 75 (6) *The plug next to the data plate should be inspected for any signs of a fuel leak or stain around the plug. (7) *The impact tubes should be inspected for fuel which would indicate a leaking regulator seal. AVStar Fuel Systems. All Rights Reserved APPENDIX A May 27, 2022 Page | 47...
Page 77 A. Refer to Lycoming Service Instruction 1532 for applicability and the specific engine and/or airframe parts catalog for further details. Figure A-5 Air Bleed Injection Nozzle Features AVStar Fuel Systems. All Rights Reserved APPENDIX A May 27, 2022 Page | 49...
Page 78 (4) *The vent tube or vent hole should be inspected for any signs of a fuel leak or stain. (5) *The lower cover should be inspected for any signs of a fuel leak or stain. Figure A-6 Flow Divider (Fuel Manifold) Features APPENDIX A AVStar Fuel Systems. All Rights Reserved Page | 50 May 27, 2022...

This manual is also suitable for:

Lfr-nmlh10 Lfr-nnlh10 Lfr-nnls10 Lfr-nnsh10 Lfr-nnsm10

AVSTAR LFR-NNSS5 Installation, Operation & Maintenance Manual

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Need help?

Questions and answers

Summary of Contents for AVSTAR LFR-NNSS5

Page 3: Record Of Revisions

Page 5: Service Document List

Page 8: Table Of Contents

Page 12: List Of Figures

Page 14: List Of Tables

Page 16: Abbreviations And Acronyms

Page 18: Introduction

Page 26: Airworthiness Limitations

Page 29: General

Page 30: Maintenance Practices

Page 32: Time Limits / Inspections

Page 34: Scheduled Maintenance Checks

Page 41: Cleaning

Page 42: Fuel Inlet Strainer

Page 43: Injection Nozzle Cleaning

Page 45: Unscheduled Corrective Maintenance

Page 46: Volcanic Ash/Particulate Contamination

Page 48: Unscheduled Servicing

Page 53: Air Intake

Page 55: Engine

Page 57: Engine Fuel System

Page 58: Servo Fuel Injector Installation Preparation Requirements & De-Preserving

Page 59: Servo Fuel Injector Installation

Page 61: Injection Nozzle Replacement

Page 62: Injection Nozzle Fuel Flow Check

Page 63: Flow Divider Replacement

Page 64: Flow Divider Storage & Preservation

Page 66: Power Control

Page 68: Servo Fuel Injector Fuel Pressure Limitations

Page 70: Model Lfr-Nnss5 Identification Of Features

Page 72: Model Lfr-Nnsh10 Identification Of Features

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AVSTAR LFR-NNSS5 Installation, Operation & Maintenance Manual

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