Appendix_I_-_UUT_Test_Specifiactions.pdf

LUBE ACCESSORY TEST STAND

Appendix I: UUT Test Specifications

UUT’S T.O. NUMBER PAGE

F101 Fuel/Oil Cooler 7J1-84-3 2-1, 7-1 through 7-4, (Lube Accessory

Test Stand 3C3966

Testing only)

F101 Hydraulic Pump 7J4-2-57-3 2-3, 6-1 through 6-5, 6-13 through 6-16

(Lube Accessory

Test Stand 3C3966

Testing only)

F101 AFT Tank Assembly 7J10-19-3 2-2, 7-1 through 7-

16, F101 Lube Flow Sensor Assembly 7J14-4-3 2-1, 7-1 through 7-3

(Lube Accessory

Test Stand 3C3966

Testing only)

F101 Oil Level Temperature Sensor 7J14-5-3 2-1, 7-2 through 7-6

(Lube Accessory

Test Stand 3C3966

Testing only)

F108 Servo Fuel Heater 6J24-10-13 (6J24-10-3) 112.1 through 112.3,

112.13 through

112.17

(Lube Accessory

Test Stand 3C3966

Testing only)

F108 Oil/Fuel Heat Exchanger 7J1-85-13 (7J1-85-3) 116.1, 116.3, 116.5 through 116.7,

116.12 through

116.15

(Lube Accessory

Test Stand 3C3966

Testing only)

F110 Hydraulic Cooler 2J-F110-3-10 WP 019 7 through 21

F110/F118 Fuel/Oil Cooler 7J1-91-3 2-1, 7-1 through 7-4, 7-9, 7-13

(Lube Accessory

Test Stand 3C3966

Testing only)

F110 Oil Tank Assembly 7J10-22-3 2-2, 6-1 through 6-4, 7-1 through 7-25

F110 Hydraulic Pump 7J4-2-60-3 2-3, 6-1 through 6-6, 6-13 through 6-17

(Lube Accessory

Test Stand 3C3966

Testing only)

`F110 Oil Differential Pressure Switch 8S2-5-8-3 2-1, 7-1, 7-3 through

7-8

(Lube Accessory

Test Stand 3C3966

Testing only)

F110 Fuel, Lube and Hydraulic Oil

Cooler

7J1-96-3 2-1, 7-1 through 7-15

(Lube Accessory

Test Stand 3C3966

Testing only)

F118 Oil Tank Assembly 7J10-23-3 2-1, 6-1 through 6-

10, 7-1 through 7-10

Adapter Kits and Fixture Information

Contractor shall supply all Adapter Kits (including hoses, fittings, tubes, caps, measuring sections, etc.) and Fixtures required for testing all the Lube Accessory Components listed above.

Duplicate items are not required, nevertheless the Contractor shall adopt a worst case scenario approach when analyzing which Adapter Kit items and fixtures to supply. For example, if a 5’ hose assembly is used on multiple Lube Accessory Components F101 and F108 and (2) hoses are required for the F101 and (6) for the F108. Contractor shall provide a minimum of (6) 5’ hoses.

T.O. 7J1-84-3

TECHNICAL MANUAL

OVERHAUL INSTRUCTIONS

WITH

ILLUSTRATED PARTS BREAKDOWN

FUEL/OIL COOLER

(USED ON F101-GE-102 ENGINE)

PART NO. CONTROL DWG. NO.

UA538411-3 9334M69P02

(ATOS)

(United Aircrafts Products)

(GE Aircraft Engines)

F33657-81-C-2006

DISCLOSURE NOTICE: This information is furnished upon the condition that it will not be released to another nation without the specific authority of the Department of the Air Force of the United States, that it will be used for military purposes only, that individual or corporate rights originating in the information, whether patented or not, will be respected, that the recipient will report promptly to the United States, any known or suspected compromise, and that the information will be provided substantially the same degree of security afforded it by the Department of Defense of the United States. Also, regardless of any other markings on the document, it will not be downgraded or declassified without written approval of the originating United States agency.

DISTRIBUTION STATEMENT D: Distribution authorized to Department of Defense and U.S. DoD contractors only, Critical Technology, 15 June 2011. Refer other requests for this document to OC-ALC/GKGBAA, Tinker AFB, Oklahoma 73145-3031.

WARNING: This document contains technical data whose export is restricted by the Arms Export Control Act (Title 22, U.S.C. 2751 et seq.) or the Export Administration Act of 1979, as amended, Title 50, U.S.C., App. 2401, et seq. Violation of these export-control laws is subject to severe criminal penalties. Dissemination of this document is controlled under DoD Directive 5230.25.

HANDLING AND DESTRUCTION NOTICE: Destroy by any method that will prevent disclosure of contents or reconstruction of the document.

Published under authority of the Secretary of the Air Force

15 NOVEMBER 2010 CHANGE 1 - 15 JUNE 2011

INSERT LATEST CHANGED PAGES. DESTROY SUPERSEDED PAGES.

LIST OF EFFECTIVE PAGES

NOTE: The portion of the text affected by the changes is indicated by a vertical line in the outer margins of the page. Changes to illustrations are indicated by shaded or screened areas, or by miniature pointing hands.

Dates of issue for original and changed pages are:

Original . . . . . . . . . . . . . . . . . . . . 0 . . . . . . . 15 November 2010 Change . . . . . . . . . . . . . . . . . . . . 1 . . . . . . . . . . . . . . 15 June 2011

TOTAL NUMBER OF PAGES IN THIS MANUAL IS 36, CONSISTING OF THE FOLLOWING:

Page *Change Page *Change Page *Change No. No. No. No. No. No.

Title A i - iii iv Blank v vi Blank 1-1 - 1-2 2-1 2-2 Blank 3-1 3-2 Blank 4-1 4-2 Blank 5-1 - 5-2 6-1 6-2 Blank 7-1 7-2 - 7-3 7-4 - 7-5 7-6 8-1 - 8-9 8-10 Blank

*Zero in this column indicates an original page

A Change 1 USAF

TABLE OF CONTENTS

Chapter Page Chapter Page

INTRODUCTION.......................................................iii 7.2 Testing.........................................................7-1

7.2.1 Test Conditions and Test Setup .................7-1

7.2.2 Bypass Valve Assembly Testing ...............7-1

SAFETY SUMMARY.................................................v 7.2.3 Oil Circuit Pressure Drop Test ..................7-3

7.2.4 Fuel Circuit Pressure Drop Test ................7-4

7.2.5 Fuel Circuit Proof Pressure Test................7-4

1 GENERAL INFORMATION...................................1-1 7.2.6 Oil Circuit Set-Up ......................................7-5

7.2.7 Oil Circuit Proof Pressure Test..................7-5

1.1 Purpose and Description.............................1-1 7.3 Preservation.................................................7-5

1.2 Leading Particulars .....................................1-1

8 ILLUSTRATED PARTS BREAKDOWN...............8-1

2 SPECIAL TOOLS, TEST EQUIPMENT,

AND CONSUMABLE MATERIALS ................2-1

SECTION I FOREWORD .....................................8-1

2.1 General........................................................2-1

2.2 Consumable Materials ................................2-1 8.1 General........................................................8-1

8.2 Models Covered..........................................8-1 3 DISASSEMBLY .......................................................3-1 8.3 Finding Part Numbers, Illustra-tion, Description ....................................8-1

3.1 General........................................................3-1 8.3.1 Maintenance Parts List ...............................8-1

3.2 Unpacking ...................................................3-1 8.3.2 Figure and Index Number Col-

3.3 Disassembly ................................................3-1 umn.........................................................8-1

8.3.3 Part Number Column .................................8-14 CLEANING ..............................................................4-1

8.3.4 CAGE Column ...........................................8-2

8.3.5 Description Column....................................8-24.1 General........................................................4-1

8.3.6 Units Per Assembly Column......................8-24.2 Cleaning ......................................................4-1

8.3.7 Usable On Code Column ...........................8-3

8.3.8 Source, Maintenance, And Re-5 INSPECTION, REPAIR, AND RE-coverability (SMR) Code Col-PLACEMENT ......................................................5-1 umn.........................................................8-3

8.3.9 Numerical Index .........................................8-35.1 General........................................................5-1

8.3.10 Reference Designator Index .......................8-35.2 Inspection....................................................5-1

8.4 Repair Parts Kits.........................................8-35.3 Repair..........................................................5-1

8.5 Usable on Codes.........................................8-35.4 Replacement................................................5-1

8.6 Source, Maintenance, and Recov-

erability (SMR) Codes...........................8-36 ASSEMBLY..............................................................6-1

8.7 Parts Standardization ..................................8-3

8.8 Commercial And Government6.1 General........................................................6-1

Entity (CAGE) .......................................8-36.2 Assembly.....................................................6-1

SECTION II MAINTENANCE PARTS7 TESTING ..................................................................7-1

LIST......................................................................8-7

7.1 General........................................................7-1

LIST OF ILLUSTRATIONS

Number Title Page Number Title Page

1-1 Fuel/Oil Cooler ............................................... 1-2 7-2 Oil Circuit Pressure Drop Test Connec- 7-1 Bypass Valve Test Connections to tion to 3C3966 Test Stand......................... 7-2

3C3966 Test Stand..................................... 7-2 i

7-3 Oil Circuit Proof Pressure Test Connec- 7-5 Fuel Circuit Pressure Drop Test Con-tions to 3C3970 Test Stand ....................... 7-3 nection to 3C3970 Test Stand ................... 7-6

7-4 Fuel Circuit Proof Pressure Test Con- 7-6 Oil Circuit Air-Bleed to 3C3970 Test nection to 3C3970 Test Stand ................... 7-4 Stand ........................................................... 7-6

8-1 Fuel/Oil Cooler - Exploded View .................. 8-8

LIST OF TABLES

Number Title Page Number Title Page

1-1 Leading Particulars............................................ 1-1 5-1 Inspection .......................................................... 5-1 2-1 Special Tools and Test Equipment................... 2-1 5-2 Nondestructive Inspection - Fluorescent- 2-2 Consumable Materials....................................... 2-1 penetrant ....................................................... 5-2 ii

INTRODUCTION

1. PURPOSE. F Follows

4. ABBREVIATIONS.This technical manual provides information required to support overhaul and testing of fuel/oil cooler. The cooler

All abbreviations used in this manual are in accordanceis manufactured by United Aircraft Products Inc, Dayton with ASME Y14.38M for use on drawings, specifications,International Airport, Box 1355, Dayton, OH 45401. The standards, and in technical documents, except as follows:cooler is used on General Electric F101-GE-102 engines.

AR As Required2. SCOPE.

AP Attaching Parts NHA Next Higher AssemblyChapter 1 through Chapter 7 of this manual contain over- SMR Source, Maintenance, and Recoverabilityhaul and test procedures. Chapter 8 contains a parts break-down for cooler.

5. LIST OF RELATED PUBLICATIONS.

2.1 A table of contents indicates chapter, paragraph title, These publications contain information in support of thisand page numbers to help find information.

technical manual and are required to accomplish the pre-

2.2 A list of illustrations and a list of tables indicate scribed maintenance:

number, title, and page number of illustrations and tables provided.

List of Related Publications

3. SYMBOLS.

Publication The following is an explanation of symbols used if applica-

Number Publication Titleble. All symbols used in this manual are in accordance with symbols per ASME Y14.38M. 00-5-1 AF Technical Order System

6. LIST OF APPLICABLE TIME COMPLIANCE- Not illustrated

TECHNICAL ORDERS.

* Requisition this marking in accordance with the requirements of AFI 37-162 The following list of Time Compliance Technical Orders

(TCTOs) affect the technical content of this manual. Only# Detail parts are listed in a separate man-current TCTOs are listed. A TCTO is deleted from this listual when rescinded, superseded, or fully incorporated.

= Alternate Part

List of Time Compliance Technical Orders

TCTO TCTO TCTO

Number Title Date

None applicable

7. IMPROVEMENT REPORTS.

Recommended changes to this manual shall be submitted on AFTO Form 22 in accordance with T.O. 00-5-1.

iii/(iv blank)

SAFETY SUMMARY

1. DEFINITIONS. 3. PROCESSING.

The following definitions apply to WARNINGS, CAU- The overhaul methods and procedures described in this TIONS, and NOTES found throughout this publication. technical manual are intended as normal overhaul practice.

Any deviations from these procedures and sequencing must first be evaluated and approved by local cognizant authority

WARNING and documented per T.O. 00-5-1 in order to ensure the deviations are consistent with standard engineering prac-tices and will neither decrease the quality of the overhauledAn operational or maintenance procedure, prac-end item nor increase the possibility of physical injury totice, condition, statement, etc., which if not those who use them. However, torque limits, calibrationstrictly observed, could result in injury to or limits, and other special values or limits shall be strictlydeath of personnel.

adhered to.

4. GENERAL PRECAUTIONS.CAUTION

ASBESTOS/CADMIUM. This engine and the support equipment called out to maintain and repair it, may containAn operational or maintenance procedure, prac-small amounts of asbestos or cadmium. When workingtice, condition, statement, etc., which if not with this engine, the following precautions shall be rigidlystrictly observed, could result in damage to or adhered to:destruction of equipment or loss of mission effectiveness.

• Parts: A limited number of parts, such as bolts, nuts, and fasteners are cadmium plated. Since you can notNOTE visually determine if a part contains asbestos or cadmium or if it is cadmium plated, refer to your Illustrated PartsAn essential operational or maintenance proce- Breakdown (IPB) (T.O. 2J-F101-4) to find these parts.dure, condition, or statement which shall be Before handling, replacing or disposing of parts containinghighlighted.

asbestos or cadmium, ensure all environmental controls are strictly followed.2. SAFETY.

• Repairs: It is highly recommended that parts contain-This publication is intended to provide safe procedures and ing asbestos or cadmium not be repaired. If, however,processes for accomplishing the maintenance herein mechanical removal of material such as grinding, buffing,described. It is, therefore, important that the warnings of drilling and sanding is necessary, appropriate personalpossible personnel injury be thoroughly understood and protective equipment and national environmental controlsobserved by the users of this manual. Changes or additions must be strictly complied with. Ensure Material Safetydeemed necessary for safety improvements should be sub- Data Sheets are available and followed for all of themitted through channels to the prime ALC in accordance materials used during any process or operation.with T.O. 00-5-1. The users of this manual should also be knowledgeable of the safety requirements outlined in the Air Force Occupational Safety and Health standards (AFOSH), especially as they apply to safe maintenance practices.

v/(vi blank)

CHAPTER 1

GENERAL INFORMATION

1.1 PURPOSE AND DESCRIPTION. bypass valve. Fuel flowing through the tube bundle cools oil flowing around the tubes.

The fuel/oil cooler (Figure 1-1) is a two-pass heat

1.2 LEADING PARTICULARS.exchanger. The cooler consists of a tube bundle, shell, and

The leading particulars of cooler are given in Table 1-1.

Table 1-1. Leading Particulars

Characteristics Specifications Weight (dry) 13.6 pounds max

Dimensions

Length 12.88 inches max

Diameter 3.98 inches max

Fuel Circuit

Type fuel Turbine fuel, aviation, Grade JP-4, MIL-T-5624

Operating pressure 1,280 psig max

Burst pressure 2,200 psig max

Proof pressure 1,650 psig

Oil Circuit

Type oil Lubricating oil, aircraft turbine engine, synthetic base, MIL-L-7808

Operating pressure 300 psig

Proof pressure 750 psig

Burst pressure 1,000 psig

Oil temperature (inlet) 100°-400°F

Oil flow (normal range) 1.5-10.5 gpm

Oil flow (extreme range) 30 gpm surge

Bypass valve cracking pressure 41-47 psid

Bypass valve reseat pressure (minimum) 36 psid

1-1

Figure 1-1. Fuel/Oil Cooler

1-2

CHAPTER 2

SPECIAL TOOLS, TEST EQUIPMENT, AND CONSUMABLE MATERIALS

2.1 GENERAL. 2.2 CONSUMABLE MATERIALS.

No special tools are required for disassembly or assembly Table 2-2 lists consumable materials used during cooler of fuel/oil cooler. Fixtures required for testing fuel/oil overhaul.

cooler are supplied as part of test stands. Table 2-1 lists special tools and test equipment that are provided. If listed equipment is not available, equivalent equipment may be used.

Table 2-1. Special Tools and Test Equipment

Tool or Equipment Figure Use and Number Number Nomenclature Application 3C3966 --- Lube accessory test stand Testing

(Refer to T.O. 33D4-6-668-1)

3C3970 --- Fuel accessory test stand Testing (Refer to T.O. 33D4-6-670-1)

3C3970G05-OC001 --- Fuel accessory test stand Testing (Refer to 1TL32-6670-1)

268687 --- Flushing stand Cleaning

8511631 --- Adapter fitting Cleaning

Table 2-2. Consumable Materials

Nomenclature Specification or Part Number CAGE General Use Brush, soft-bristle H-B-491 Cleaning

Calibration fluid MIL-C-7024, Type II Test fluid

Chemical film MIL-C-5541 Protective coating

Cloth, abrasive P-C-451 Metal removal

Cloth, crocus P-C-458 Blending and polishing

Cloth, lint-free CCC-C-46 Cleaning

Oil MIL-L-7808 Test fluid and lubricant

Paper, barrier MIL-B-121 Protective wrapping

Solvent, drycleaning P-D-680, Type II Cleaning

Stone, Arkansas SS-S-736 Removing high metal

Wire, safety MS20995C32 Safety-wiring parts

Change 1 2-1/(2-2 blank)

1374774529C Highlight

1374774529C Highlight

CHAPTER 3

DISASSEMBLY

3.1 GENERAL.

NOTE

This chapter covers unpacking and disassembly of fuel/oil cooler. Determine extent of disassembly required by pre- If necessary, a soft-jawed vise may be used to liminary visual inspection and test. Do not disassemble any hold bypass valve during the following step.

part unless replacement or servicing is required, or unless removal is required to gain access to other parts requiring d. Place bypass valve cage (11) in arbor press with replacement or servicing. hex head and retaining ring facing up.

3.2 UNPACKING.

WARNING

No special instructions are required for unpacking cooler.

Save and store all packaging material for reuse for ship-

Tension of poppet spring (6) must be controlledment or storage purposes.

to prevent injury to personnel and to enable parts to be removed3.3 DISASSEMBLY.

e. Using a 1/2 inch rod of sufficient length, pushThe disassembly procedures are described in detail unless down on valve cap (4) to relieve pressure onself-evident upon inspection. Figure 8-1 shows the general retaining ring (3).order of disassembly and shall be used as a reference for removing valve assembly and other parts of cooler. Note f. Remove retaining ring (3).

that attaching parts immediately follow parts they attach.

Proceed as follows: g. Slowly release pressure on poppet spring (6).

h. Remove valve cap (4), valve poppet (5), and pop- CAUTION pet spring (6) from bypass valve cage (11).

i. Remove preformed packing (7) and backup ring (8)• Do not allow any parts to come in contact from valve cap (4). Discard preformed packing and with dirt or grit after they have been backup ring.

removed.

j. Remove preformed packings (9 and 10) from• Removed preformed packings shall not be bypass valve cage (11). Discard preformedreused.

packings.

a. Cut and discard safety wire that is attached to

k. Remove screw thread inserts (12 and 13) frombypass valve cage (11).

cooler weldment (14) only if repair and/or replace-ment is required (paragraph 5.3 and paragraph 5.4).b. If installed, remove shipping covers (15 and 16).

c. Remove valve assembly (2) from cooler weldment (14).

3-1/(3-2 blank)

CHAPTER 4

CLEANING

4.1 GENERAL. (4) Clean cooler weldment by cycle-flushing with P-D-680 solvent for about 1 hour. Maintain

This chapter specifies cleaning method and type of cleaning back pressure at about 29 PSIG and reverse flow to be used with fuel/oil cooler. every 5 to 15 minutes. Periodically shake weld-ment while flushing, to aid in removing metal

4.2 CLEANING. chips or other solids. Longer flushing may be

required when contamination is unusually Clean components of cooler as follows: severe.

(5) Use NAS 1638, class 7 particle count to deter- WARNING mine if weldment is clean. Continue flushing operation until fluid sample meets the above requirements.P-D-680, Type II is flammable and irritating to the skin, eyes, and respiratory tract. Wear gog-gles and other protective clothing, as necessary. WARNING Use in a well-ventilated area or an approved cleaning cabinet, and keep away from heat, sparks, and open flame. Use approved personal protective equipment

(eye goggles or face shield) when using com-

a. Clean external surfaces of cooler weldment pressed air. Maximum allowable pressure for

(Figure 8-1, 14) with P-D-680 solvent. Use a soft- cleaning operations is 30 PSIG. Provide protec-bristle brush moistened with solvent to remove tion from flying particles. Do not direct air-stubborn deposits and stains. Allow weldment to stream toward self or others.

air dry.

(6) Hold cooler weldment so that all solvent drains

b. Cycle flush cooler weldment (14) as follows: out. Dry with a lint-free cloth or dry compressed air.

(1) Install 8511631 adapter fittings on fuel ports and oil ports of weldment. c. Clean valve assembly components with P-D-680 solvent. Use a soft-bristle brush to remove all

(2) Mount weldment on 268687 flushing stand table deposits or varnish. Dry parts with a line-free cloth with oil side inlet and outlet ports facing down, or dry compressed air.

if possible.

(3) Connect hoses from 268687 flushing stand to 8511631 adapter fittings.

4-1/(4-2 blank)

CHAPTER 5

INSPECTION, REPAIR, AND REPLACEMENT

5.1 GENERAL. tubes that are visible through ports. Remove all trapped fibers and metal chips.

This chapter provides instructions for inspection, repair,

5.3 REPAIR.and replacement of worn, damaged, or defective parts.

Excessive wear is any obvious deformation or deterioration Repair of cooler consists of removing high metal. Use P-C-of parts that may stop the fuel/oil cooler from working. If 451 crocus cloth or an Arkansas stone.any doubt exists about serviceability of a part, replace part.

5.4 REPLACEMENT.5.2 INSPECTION.

For replacement of any screw-thread inserts (12 and 13,Visually inspect all parts listed in Table 5-1 under a bright Figure 8-1), refer to TO 44H1-1-117.light. Dimensional checks are not required. Inspect core

Table 5-1. Inspection

Part and Index Number Type of Corrective (Figure 8-1) Inspection Inspect for Action

Valve cap (4) Visual Cracks Cracks not acceptable. Replace cap

Distortion, or nicks Distortion and nicks acceptable if valve assembly passes test.

Remove high metal (paragraph 5.3)

Valve poppet (5) Visual Cracks, distortion, or nicks Cracks and distortion not acceptable. Replace. Nicks acceptable if not on sealing surface. Remove high metal (paragraph 5.3)

Bypass valve cage Visual Cracks, distortion, or nicks Cracks and distortion not

(11) acceptable. Replace. Nicks acceptable if not on sealing surface. Remove high metal (paragraph 5.3)

Poppet spring (6) Visual Cracks or distortion Not acceptable. Replace

Screw thread inserts Visual Damage No damage acceptable. Replace (12 and 13) inserts (paragraph 5.4)

Cooler weldment (14) Visual Dents that do not exceed 0.025 Acceptable without repair, if inch in depth with a radius of at they do not cross a baffle or least 0.060 inch weld. If damage exceeds limit, retain part for future disposition determination.

5-1

Table 5-1. Inspection - Continued

Part and Index Number Type of Corrective (Figure 8-1) Inspection Inspect for Action

Visual Gouges, scratches, and nicks on Acceptable. Blend to remove oil port bosses, mounting lugs, high metal and stress risers. If and fuel end domes (except damage exceeds limit, retain sealing surfaces) that do not part for future disposition deter-exceed 0.010 inch deep mination

Visual Gouges, scratches, and nicks on Acceptable. Blend to remove shell that are less than 0.003 high metal and stress risers. If inch deep or cannot be felt with damage exceeds limit, retain a sharp-pointed scribe part for future disposition deter-mination

Visual Gouges, scratches, and nicks on No damage acceptable on seal-fuel and oil port pads ing surface areas. Remove mi-nor damage by using P-C-451 abrasive cloth on a flat surface and rubbing in a circular pat-tern. Pad surface shall be flat within 0.006 inch TIR. Sweep with a dial indicator on a sur-face plate or check with a straight edge and a 0.006 inch feeler gage

Fluorescent penetrant Cracks in weld areas Cracks are not acceptable.

(Table 5-2) Retain part for future disposi-tion determination. The shell-to-header braze and tack weld joints do not require inspection unless weld repair is evident on these joints. Any weld longer than 1/2 inch on these joints is a weld repair. No cracks are permitted in the weld repair

Table 5-2. Nondestructive Inspection - Fluorescent-penetrant

Type IPart (Figure 8-1 Penetrant Dwell Developer Dwell Method Sensitivity Level Index Number) (minutes) (minutes)

Cooler weldment A 1 15 minimum 4 maximum (14)

*Fluorescent-penetrant inspect in accordance with MIL-STD-6866 and TO 33B-1-1. Method D, sensitivity level 2 may be used as an alternate.

5-2

CHAPTER 6

ASSEMBLY

6.1 GENERAL. d. Assemble valve poppet (5), poppet spring (6), and valve cap (4) in bypass valve cage (11).

This chapter provides assembly instructions for fuel/oil cooler. When assembling cooler, observe the following:

WARNING

a. Replace all nonmetallic parts at each overhaul.

Tension of poppet spring (6) must be controlled to prevent injury to personnel and to enableWARNING parts to be installed.

Lubricating oil in liquid, vapor, or mist form is e. Place cooler weldment (14) in an arbor press.

flammable, irritating to the skin and respiratory Using a 1/2-inch diameter rod and arbor press, tract, and poisonous in the digestive tract. compress valve cap (4) and poppet spring (6) to Remove saturated clothing, wash skin well, clear retaining ring groove.

don’t swallow liquid, and don’t breath mist and

f. Install retaining ring (3) in groove of bypass valvevapors.

cage (11). Slowly release pressure from valve cap.

b. Apply thin film of MIL-L-7808 oil to all preformed

g. Remove valve assembly (2) from press. Test valvepackings and surfaces over which packings pass.

assembly (paragraph 7.2).

6.2 ASSEMBLY.

h. Screw valve assembly (2) into cooler weldment (14). Torque valve assembly (2) 60-67 foot-See Figure 8-1 and proceed as follows:

pounds. Safety-wire valve assembly (2) to cooler

a. Install preformed packings (9 and 10) in grooves weldment (14).

on bypass valve cage (11).

i. Test cooler (Chapter 7).

b. Clamp bypass valve cage (11) in a soft-jawed vise with retaining ring groove facing up.

c. Install preformed packing (7) and backup ring (8) on valve cap (4).

6-1/(6-2 blank)

CHAPTER 7

TESTING

7.1 GENERAL. testing oil section of cooler on 3C3966 test stand.

Refer to T.O. 33134-6-668-1 for identification of

The tests in this chapter shall be performed before and after fittings, hoses, and test connection ports.

assembly to ensure that fuel/oil cooler will operate satisfac-

e. The instructions throughout this chapter use signif-torily. If bypass valve or cooler fails any tests in this icant item number (SIN) references that apply tochapter, refer to Chapter 3 and Chapter 5 for applicable applicable test stand.disassembly and repair procedures. After assembly, repeat test procedures in this chapter.

7.2.2 Bypass Valve Assembly Testing. Test valve as

7.2 TESTING. follows:

a. Install bypass valve in 136138904 test fixture.The following paragraphs contain instructions for minimum operational performance tests of cooler. Paragraph 7.2.2

b. Connect lines to test fixture (Figure 7-1). Followprovides information for testing the bypass valve assembly notes on Figure 7-1 for connecting line to oil- out(Figure 8-1, 2). The remaining steps provide information port.for testing assembled fuel/oil cooler. Refer to Table 2-1 for test equipment listing. (1) Disconnect outlet port and measure leakage in graduated cylinder.

7.2.1 Test Conditions and Test Setup.

c. Perform cracking pressure test as follows:

(1) Place beaker 2803C under outlet.WARNING

(a) Press 733AA pump start button.

Lubricating oil in liquid, vapor or mist form is

(b) Select E* F101 tests on Micro-Flo 100flammable, irritating to the skin and respiratory computer.system, and poisonous in digestive tract.

Remove saturated clothing and wash skin well.

(c) Select AB* Fuel Oil Cooler test on Micro FloDon’t swallow liquid and don’t breathe mist

100 computer. Open valves 539BN, 539BP,and vapor.

242GE, and 263PA.

a. Conduct all tests with MIL-C7024 calibration fluid

(2) Using regulator 290CB, smoothly increase oiland MIL-L-7808 oil. Maintain fluid temperature pressure until valve poppet cracks open. Thisand room ambient temperature between 60° and will be indicated by a sudden increase in flow100°F. Maintain barometric pressure between 24 (over 50cc per minute) at the oil-out port.and 30.5 inches Hg.

(3) Record (061LA) inlet pressure reading. Pressureb. Continually monitor external surfaces for leaks must be 41-47 PSIG. If out-of-limits, replaceduring all tests.

poppet spring (Figure 8-1, 6).

c. The 3C3970 fuel accessory test stand can be used

(4) There must be no sign of valve chatter, and noto test fuel section of cooler. However, other fuel pressure or flow oscillations.accessory test stands can also be used. Test stand 3C3970G05-OC001 may be used as an equivalent d. Perform poppet leakage test as follows:

stand to 3C3970. Figure 7-3, Figure 7-4, and Figure 7-5 show test fittings and connections for (1) Using regulator 290CB, set 061LA inlet pres-testing fuel section of cooler on 3C3970 test stand. sure to a minimum of 47 PSIG. Slowly reduce Refer to T.O. 33D4-6-670-1 or Manual 1TL32- inlet pressure to 36-40 PSIG.

6670-1 for identification of fittings, hoses, and test connection ports. (2) Using 2803C beaker, measure leakage at oil- out port. Leakage shall not exceed 150 cc per min-

d. The 3C3966 lube accessory test stand can be used ute. If leakage exceeds limits, check seat of to test oil section of cooler. However, other lube bypass valve cage (11) and valve poppet (5).

accessory test stands can be used. Figure 7-1 and Replace damaged part.

Figure 7-2 show test fittings and connections for

Change 1 7-1

Figure 7-1. Bypass Valve Test Connections to 3C3966 Test Stand

Figure 7-2. Oil Circuit Pressure Drop Test Connection to 3C3966 Test Stand

7-2

1374774529C Highlight

Figure 7-3. Oil Circuit Proof Pressure Test Connections to 3C3970 Test Stand

(3) Using 290CB regulator, reduce inlet pressure to (7) Disconnect lines from test fixture.

zero as read on Micro-Flo computer (061LA).

(8) Remove bypass valve from test fixture. If valve

e. Perform full-flow pressure drop test as follows: passed all tests, package valve and return it to assembly.

(1) Connect line to oil-out port of test fixture

(Figure 7-1). 7.2.3 Oil Circuit Pressure Drop Test. Proceed as follows:

(2) Using 290CB regulator, increase inlet pressure to establish flow of 9.85±0.1 gpm. a. Connect fittings and lines to cooler (Figure 7-2).

(3) Record the pressure drop. b. Select Menu A8*. Open 249LN, 249LP, 242GE, and 263PA valves.

NOTE

c. Using 290CB regulator, increase inlet pressure to establish 024AA gage minimum flow of 9.85 ±0.1Fixture pressure drop is obtained by using a gpm.plug (part of fixture) in the test fixture in place of the bypass valve.

d. Record differential pressure between oil-in and oil-out ports.(4) Establish same conditions as in step (2) and record differential pressure. Once obtained,

e. Using 290CB regulator, decrease inlet pressure tocheck monthly or as needed to ensure that there zero.has been no change.

f. Disconnect lines from oil-in and oil-out ports and(5) Subtract fixture pressure drop recorded in step connect the lines together. Using 290CB regulator,(4) from value recorded in step (3). This is the increase inlet pressure to establish 024AA gagebypass valve pressure drop. Maximum pressure minimum flow of 9.85 ±0.1 gpm.drop across bypass valve shall be 60 psid.

Replace poppet spring (Figure 8-1, 6) or dam- g. Record tare differential pressure. Once obtained, aged part if out-of-limits. check monthly or as needed to ensure that there has been no change.(6) Using 290CB regulator, decrease inlet pressure to zero. Close 539BN, 539BP, 539BE, 242GE h. Using 290CB regulator, decrease inlet pressure to and 263PA valves. zero.

7-3

Figure 7-4. Fuel Circuit Proof Pressure Test Connection to 3C3970 Test Stand

i. Turn 200CA valve to closed position to isolate f. Disconnect lines from cooler. Prop cooler to mini-cooler from the system. Maintain pressure for a mize fluid loss.

minimum of 5 minutes.

g. Cap FUEL-OUT line with 2133C, and FUEL- IN

j. Close 249LN, 249LP, 249GE, and 263PA valves. line with 2103R, 2100X, and 2133N.

k. Subtract pressure recorded in step g from value 7.2.5 Fuel Circuit Proof Pressure Test. Proceed as recorded in step d. This is the oil circuit pressure follows:

drop. The pressure drop shall not exceed 28 psid. If out-of-limits, check bypass valve and cooler weld- a. Connect fittings and lines to cooler as shown in ment oil circuit. Figure 7-4 .

l. Remove lines and adapters from cooler ports. NOTE

7.2.4 Fuel Circuit Pressure Drop Test. Proceed as

Cooler will be kept upright to minimize fluid follows: loss.

a. Connect fittings and lines to cooler (Figure 7-5). b. Prop cooler so that liquid height gauge is upright.

Fill gauge to 2 inch mark.b. Select Menu A1*. For 3C3970G05-OC001, select corresponding test screen for the pressure drop test. c. Pump pressurizing fluid through fuel circuit until bubbles no longer appear at cooler FUEL OUTc. Using 242GC and 244AA valves, establish a flow ports. Seal off cooler FUEL OUT ports.through fuel circuit 534AB of 150 ±5 pounds per minute. Bleed air from lines using 210CN and d. Adjust 290DA and 250FA regulators to set 1650 210CP valves. +25-0 psi on 539BA. Turn 200CA valve to OPEN.

d. Record differential pressure (539BP/539BQ) e. There shall be no change in liquid height gage between FUEL-IN and FUEL-OUT ports. Pressure displacement or distortion of cooler during last drop shall not exceed 28 psid. If out-of- limits, minute of test.

repeat fuel circuit cleaning.

f. Adjust 250FA regulator to set zero on 079UA.

e. Using 242GC and 244AA valves, decrease flow through fuel circuit to zero. g. Adjust 290DA regulator until tension is released.

Adjust 250FA regulator until pressure on 079KA

7-4 Change 1 drops to zero. Adjust 250FA regulator counter- g. Adjust 290DA regulator until tension is released.

clockwise to release. Adjust 250FA regulator until pressure on 079KA drops to zero. Adjust 250FA regulator counter-

h. Disconnect line and remove fittings from cooler. clockwise to release. Remove liquid height gauge and cap FUEL- OUT port with 2133C. Cap

i. Fully drain all fluid from both circuits of cooler. FUEL-IN line with 2103R, and 2133N.

h. Disconnect line from cooler.7.2.6 Oil Circuit Set-Up.

7.3 PRESERVATION.a. Connect fittings and lines to cooler (Figure 7-6).

Preserve cooler for storage or shipping as follows:b. Select Menu A1*. For 3C3970G05-OC001, select corresponding test screen for proof pressure test.

WARNINGc. Using 242GC and 244AA valves, establish a flow through oil circuit 534AB of 3 ±.5 pounds per minute. Bleed air from lines using 210CN and

P-D-680, Type II is flammable and irritating to210CP valves.

the skin, eyes, and respiratory tract. Wear gog-gles and other protective clothing, as necessary.d. Disconnect lines from cooler. Prop cooler to mini- Use in a well-ventilated area or an approvedmize fluid loss.

cleaning cabinet, and keep away from heat, sparks, and open flame.e. Cap oil-out line with 2133C, and oil-in with

2103R, 2100C, and 2133N.

a. Flush cooler with P-D-680 solvent to remove test fluids.7.2.7 Oil Circuit Proof Pressure Test. Proceed as follows:

b. Dry cooler, inside and out, to remove all flushing fluid. Cooler may be vacuum dried.

NOTE

Calibration fluid, MIL-C-7024 may be used in WARNING both circuits in place of MIL-L-7808 for proof pressure test only.

Lubricating oil in liquid, vapor or mist form is

a. Connect fittings and lines to cooler and to test flammable, irritating to skin and respiratory stand ports (Figure 7-3). system, and poisonous in digestive tract.

Remove saturated clothing and wash skin well.

b. Prop cooler so that liquid height gauge is upright. Don’t swallow liquid and don’t breathe mist Fill gauge to 2 inch mark. and vapor.

c. Pump pressurizing fluid through fuel circuit until c. Put a small amount of MIL-L-7808 oil that has bubbles no longer appear at cooler FUEL OUT been filtered to 10-microns absolute in both ports. Seal off cooler FUEL OUT ports. circuits.

d. Adjust 290DA and 250FA regulators to set 750 + d. Drain excess oil, install shipping caps, and tag unit 25 - 0 psi on 539BA. to indicate preservation oil used. There shall be no sign of leakage from fuel circuit to oil circuit.

e. There shall be no sign of leakage from oil circuit to fuel circuit. There shall be no change in liquid e. If assembly is not to be returned to service immedi-height gage displacement or distortion of cooler ately, wrap in MIL-B-121 barrier paper and pack in during last minute of test. a carton to protect it from damage.

f. Adjust 250FA regulator to set zero on 079UB.

Change 1 7-5

Figure 7-5. Fuel Circuit Pressure Drop Test Connection to 3C3970 Test Stand

Figure 7-6. Oil Circuit Air-Bleed to 3C3970 Test Stand

7-6

CHAPTER 8

ILLUSTRATED PARTS BREAKDOWN

SECTION I FOREWORD

8.1 GENERAL. index number. Index numbers shall be listed in sequence.

When the same part appears more than once on an illustra-

This Illustrated Parts Breakdown (IPB) is prepared to assist tion, and is part of different assemblies or subassemblies, or supply and maintenance personnel in requisitioning, stor- it is otherwise necessary to list it more than once, each ing, issuing, identifying parts, and for illustrating assembly listing shall be assigned a different index number. An index and disassembly relationships. This IPB is not intended to number shall not be assigned to an assembly when the be used as an authority for procedure of disassembly or detail parts are indexed unless the assembly is shown assembly. Maintenance or repair should be performed by completely assembled on the same illustration, or bracket authorized personnel using the applicable maintenance or circle shows which parts comprise the assembly. When a instructions. change to an end item requires addition of parts to a listing and illustration, the index number shall be the same as the

8.2 MODELS COVERED. preceding index number with an added decimal number, e.g. 22.1, 22.2, etc.

This Illustrated Parts Breakdown (IPB) lists and describes items necessary for support of the Fuel/Oil Cooler (used on 8.3.3 Part Number Column. This column contains part F101-GE-102 Engine), P/N UA538411-3 and Control Dwg. numbers, including dash numbers, assigned to each listed No. 9334M69P02. part in accordance with current industry engineering prac-tices. The appropriate numbers for the type, model, specifi-

8.3 FINDING PART NUMBERS, ILLUSTRATION, cation, specification control drawing, and the source con- DESCRIPTION. trol drawing shall follow the nomenclature. When the drawing number for a part is different than the part number Refer to the illustrations at end of this chapter for explana- (excluding dash number differences), the drawing number tion of: How to find a part number or description using the shall follow the description. When a part is authorized for TOC and illustration titles or How to find the illustration or local manufacture, and a specific drawing is required for description if a part number or reference designation is such accomplishment, the drawing number shall follow the known. description. When only a model or type number identifies component, such a number shall be used in lieu of a part

8.3.1 Maintenance Parts List. The MPL is separated number.

into figures by main groups or assemblies and keyed to associated illustrations by figure and index numbers. In 8.3.3.1 Commercial Hardware. Commercial hardware general, assemblies and parts installed at time end item(s) procurable from normal commercial sources is identified was manufactured are listed and identified in this manual. with the letters COML in the part number column. When When an assembly or part (including vendor items), which ordering the part, the complete description must be given.

is different from original, was installed during manufacture of later items, series or blocks, all assemblies and parts are 8.3.3.2 Parts Not Illustrated. Parts, which are indexed listed (and usable on coded). However, when original in the listing but are not shown on the illustration, shall assembly or part does not have continued application (no have a dash (-) preceding the index number.

spares of original were procured or such parts are no longer authorized for replacement), only preferred assembly or 8.3.3.3 Marking. Decalcomanias, metalcals, vinyl film part is listed. Also, when an assembly or part was installed markings, etc., shall be considered as parts. The identifying during modification and original does not have continued drawing number for each marking shall appear in the Part application, only preferred item is listed. When a standard Number column. The part number for each marking shall part can be replaced with an oversize or undersize part, the be followed (flush right) by an asterisk (*) symbol and latter parts, showing sizes, are also listed. means “requisition this marking in accordance with the requirements of AFI 37-162”. The nomenclature or title of

8.3.2 Figure and Index Number Column. The figure each marking shall appear in the description column. The number shall precede the first index number in each listing location of each marking shall be illustrated, but a separate and the first index number on each page of a multi-page readable illustration is not necessary.

listing, but shall not be repeated before each subsequent

8-1

8.3.3.4 Government Furnished Equipment (GFE) And column in which the first word of nomenclature appears.

Contractor Furnished Equipment (CFE) Covered by First item directly above, which appears one column to the left (except for attaching parts), is NHA.Separate Manuals. Following the part number of a Government Furnished Equipment (GFE) or Contractor Description Furnished Equipment (CFE) item, a number (#) symbol shall be inserted flush right. This symbol means that detail 1234567 parts are listed in a separate manual.

END ITEM, COMPONENT, MAJOR ASSEMBLY

8.3.4 CAGE Column. When a CAGE code for the ⋅ HCI DETAIL PARTS FOR END ITEM, appropriate design activity or government agency is not COMPONENT, MAJOR ASSEMBLY published in the current issues of the H4/H8 Cataloging ⋅ ASSEMBLY Handbooks, the word NONE shall be inserted in the CAGE ⋅ Attaching parts for assembly (AP) column directly opposite the part, model or type number ⋅ ⋅ Detail parts for assembly listed in the part number column. When the word NONE is ⋅ ⋅ Subassemblies listed in the CAGE column, the complete name and address ⋅ ⋅ Attaching parts for subassemblies (AP) of the design activity or government agency, whose part, ⋅ ⋅ ⋅ Detail parts for subassemblies model or type number appears in the part number column, ⋅ ⋅ ⋅ Sub-subassemblies shall be shown in parentheses at the end of the description. ⋅ ⋅ ⋅ Attaching parts for sub-subassemblies (AP) When several CAGE codes are not available, or the design ⋅ ⋅ ⋅ ⋅ Detail parts for sub-subassemblies activity’s name and address must be repeated several times,

8.3.5.2 Cross-Reference.numerically identified footnotes may be used in the CAGE column and identified at the end of the MPL.

a. The notation (See Figure _____ for detail bkdn)

8.3.5 Description Column. This column contains the following description of a part number indicates that further breakdown of part will be shown ondescription of each part listed. The identifying noun shall figure noted.be the first word. The size, dimensions, material, and tolerances for a part shall be indicated to make the descrip-

b. The notation (see Figure _____ for NHA) follow-tion complete. When the listing is an assembly or installa-ing description of a part number indicates that thetion, the word ASSEMBLY or INSTALLATION shall correct assembly relationship of the part will befollow the noun. A comma shall separate these words from shown on the figure and index noted.the balance of the description. When units of measure are the same, they shall not be repeated with each dimension; c. The notation (Intchg with _____) is used when two example: 1/8 by 3/4 inch (not 1/8 inch by 3/4 inch). To or more parts are dimensionally and functionally avoid confusion, the dash shall be used between a whole interchangeable and none are preferred over the number and a fraction; example: 1-1/16. When a decimal other. Notation is shown in the description column with a value of less than 1.0 is given, a zero shall precede of all such interchangeable parts.

the decimal point; example: 0.002 inch. The appropriate numbers for the type, model, specification, specification d. The notation (Use only on (part number)) follow-control drawing, and the source control drawing shall ing description of a part number indicates that part follow the nomenclature. When the drawing number for a is used only on part number indicated.

part is different than the part number (excluding dash number differences), the drawing number shall follow the e. The notation (When exh, use _____) following description. When a part is authorized for local manufac- description of a part number indicates an improved ture, and a specific drawing is required for such accom- or redesigned part has been developed and replaced plishment, the drawing number shall follow the description. part is still authorized for continued use until stock Reference to another illustration for information on the is depleted.

detail parts of an assembly and reference to another illustra-

8.3.6 Units Per Assembly Column. Quantity shown intion for information on the NHA shall be made. Attaching parts shall be identified by the abbreviation (AP) following this column represents units required for each detail part in the description of the part. an assembly, each assembly in the NHA, and each attach-ing part to attach one unit or one assembly. The abbrevia-

8.3.5.1 Indentation. Parts listed in the MPL are tion AR (as required) is used when quantity required must indented to indicate item relationship or Next Higher be determined when parts are installed. The abbreviation Assembly (NHA). Nomenclature of each assembly is fol- REF (reference) indicates that item has been previously lowed in the list (except for attaching parts) by nomencla- listed under its NHA. The SEE FIGURE notation in ture of its component indented one column to the right. description of item will indicate figure and index number at This indentation indicates relationship of component to which units per assembly can be determined.

assembly. To determine NHA of a part or assembly, note

8-2

8.3.7 Usable On Code Column. This column contains used with the letter F before the figure number, such as F7-

6. The letter F means follows.codes to indicate the configuration of the end items to which listed assemblies and parts apply. No code is

8.4 REPAIR PARTS KITS.required in this column if a part applies to all configura-tions or the manual covers only one configuration. The When replaceable parts of an assembly are available in thecoding system shall consist of letters of the alphabet form of kits, the words REPAIR KIT AVAILABLE shallbeginning with single letters; example: A, B, C, and follow the description of the applicable assembly. Thecontinues with double letters AA, AB, AC, when detail parts of the assembly that are contained in the kitnecessary.

shall be assigned kit source codes and these codes shall appear in the description column. Illustrations of kits are8.3.8 Source, Maintenance, And Recoverability not required.(SMR) Code Column. This column shall contain the five-digit Joint Military Services Uniform SMR codes. 8.5 USABLE ON CODES.

8.3.9 Numerical Index. The numerical index is required

When two or more assemblies are listed in the same parts when the MPL contains 200 or more different part num- list, a code letter (A, B, etc.) is assigned to each main bers. The numerical index contains the part numbers of all assembly. All subcomponents, peculiar to a particular parts listed in the MPL, including model and type numbers assembly, are identified by the same code letter as the main for components not assigned part numbers. assembly. If parts are common to all assemblies covered, the Usable on Code column is left blank.8.3.9.1 Part Number Column. Part number arrange-ment shall begin at the extreme left and continue from left 8.6 SOURCE, MAINTENANCE, AND to right, one position at a time. For the first character of the RECOVERABILITY (SMR) CODES.

part number, the letters A through N and P through Z take precedence over the numerals, 0 through 9. (Alphabetic Os This manual contains Joint Military Service Uniform are considered numeric zeros.) For the second and suc- Source, Maintenance, and Recoverability (SMR) codes.

ceeding characters of a part number, precedence is as Definitions of these SMR codes are available in T.O. 00-follows: (1) diagonal, (2) period, (3) dash, (4) letters A 25-195.

through N and P through Z, and (5) numerals, 0 through 9.

8.7 PARTS STANDARDIZATION.

8.3.9.2 Figure and Index Number Column. This col-

umn contains the figure and index numbers for all parts Authority for use of a part number different than the part listed, if applicable. When an assembly or part has not been number listed in this IPB is established by the Department assigned an index number, the figure and index number of of Defense (DoD) Interchangeability and Substitution the preceding part in the MPL shall be used with the letter (I&S) Program. Refer to the D043B Master Item Identifica- F before the figure number, such as F7-6.