Fuel_Oil_Released_2J-TF33-53-11_WP018.pdf

T.O. 2J-TF33-53-11

TECHNICAL MANUAL

MAINTENANCE INSTRUCTIONS

DEPOT

ACCESSORIES

AIRCRAFT ENGINE MODELS

TF33-P-3 TF33-P-5 TF33-P-7A TF33-P-9 TF33-P-11A

TF33-PW-100A TF33-PW-102 TF33-PW-102A

TF33-PW-102B TF33-PW-102C TF33-PW-103

Pratt & Whitney Military Engines

United Technologies Corporation F34601-92-D-0380 F34601-03-D-0121

Prepared By: Command Technology, Inc.

FA8124-15-F-0002

This publication incorporates Special Handling AFTO Form 252 510MLPSAD6W014R, OC-15-23067, Dated 2 February 2016.

If a work package is applicable to TF33-PW-102 and TF33-PW-102A, then that work package is also applicable to TF33-PW-102B and TF33-PW- 102C.

This publication is one of a set of thirteen manuals numbered T.O. 2J-TF33-53-1 through T.O. 2J-TF33-53-12 and T.O. 2J-TF33-53-2-1. The complete manual set is required for depot maintenance.

Published Under Authority of the Secretary of the Air Force

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 (APPROPRIATE SERVICE OR AGENCY) 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 THE DEPARTMENT OF DEFENSE AND U.S. DOD CONTRACTORS ONLY, CRITICAL TECHNOLOGY, 1 MAY 1992. REFER OTHER REQUESTS FOR THIS DOCUMENT TO AFLCMC/LPSLB (TOMA), TINKER AFB, OK 73145-3031. QUESTIONS CONCERNING TECHNICAL CONTENT SHALL BE

REFERRED TO AFLCMC/LPSAD.

WARNING - THIS DOCUMENT CONTAINS TECHNICAL DATA WHOSE EXPORT IS RESTRICTED BY THE ARMS EXPORT CONTROL ACT (TITLE 22, U.S.C., SECTION 2751 ET SEQ) OR THE EXPORT ADMINISTRATION ACT OF 1979, AS AMENDED (TITLE 50 U.S.C., APP 2401 ET SEQ). VIOLATIONS OF THESE EXPORT LAWS ARE SUBJECT TO SEVERE CRIMINAL

PENALTIES.

HANDLING AND DESTRUCTION NOTICE - COMPLY WITH DISTRIBUTION STATEMENT AND DESTROY BY ANY METHOD

THAT WILL PREVENT DISCLOSURE OF CONTENTS OR RECONSTRUCTION OF THE DOCUMENT.

Page 1 of 2DISTRIBUTION STATEMENT "D" Chg. Date: 15 JUNE 2016 Rev: 5

12/4/2017file://52wwyk-as-2027v.area52.afnoapps.usaf.mil/PMXG-ETIMS$/ETOS/2J-TF33-53-11-WA-1/...

15 SEPTEMBER 2012 CHANGE 5 - 15 JUNE 2016

Page 2 of 2DISTRIBUTION STATEMENT "D" Chg. Date: 15 JUNE 2016 Rev: 5

WORK PACKAGE 018 00

APPLICABLE TCTOS

NONE

TECHNICAL PROCEDURES

COOLER, FUEL COOLANT OIL

EFFECTIVITY: ENGINE MODELS TF33P-3 P-5 P-7A P-9 P-11A PW-100A

PW-102 PW-102A PW-103

REFERENCE MATERIAL REQUIRED

T.O. 2-1-111 Standard Maintenance Procedures

T.O. 2J-1-13 Cleaning of Gas Turbine Engines and Parts

T.O. 2J-TF33-53-1 Introduction and General Information

SWP 005 01 Table of Limits (P-3, -5, -9, -11A)

SWP 005 02 Table of Limits (P-7A, PW-100A)

SWP 005 03 Table of Limits (PW-102, PW- 102A)

SWP 010 02 Inspection, Flourescent Penetrant, Local Application (SPOP 70)

SWP 014 16 Anodize Touch-up, Brush or Swab (AMS 2473) (SPOP 42)

SWP 015 01 Welding, Inert Gas Fusion

T.O. 2J-TF33-53-2 Rework and Reidentification

SWP 019 01 Cooler Assembly - Fuel Coolant Oil

T.O. 44H1-1-117 General Installation of Heli-Coil Inserts

CONSUMABLE MATERIALS

CALIBRATING FLUID MIL-C-7024, TYPE II

COMPOUND, CARBON

REMOVING

P-C-111, MIL-C-19853

LOCKWIRE (AMS 5687) MS9226-04 (0.032 INCH)

Publication Number Publication Title

Nomenclature Specification Part No. CAGE Code

Page 1 of 26DISTRIBUTION STATEMENT "D" Chg. Date: 15 JUNE 2016 Rev: 5

LOCKWIRE 586821

LUBRICANT, ENGINE OIL,

SYNTHETIC

PWA 521, TYPE I MIL-L-7808

METAL, FILLER AMS 4043

OIL, LUBRICATING MIL-L-6081, GRADE 1010

PETROLATUM, WHITE (PMC

9669)

VASELINE OR EQUIVALENT

VV-P-236

SOLVENT, PETROLEUM P-D-680, TYPE II

TETRACHLOROETHYLENE

(PERCHLORETHYLENE)

O-T-236

APPLICABLE SUPPORT EQUIPMENT

PWA 10675 Stand -

PWA 16471 Fixture T1

PWA 16478 Adapter T2

PWA 16506 Wrench T3

PWA 16507 Wrench T4

PWA 17700 Puller T5

PWA 43351 Wrench T6

EXPENDABLE ITEMS

GASKET 395436 AS REQUIRED

PACKING 373342 AS REQUIRED

PACKING 373343 AS REQUIRED

PACKING 384003 AS REQUIRED

PACKING 467729 AS REQUIRED

PACKING 481600 AS REQUIRED

PACKING 481601 AS REQUIRED

PACKING 594316 AS REQUIRED

PACKING 629305 AS REQUIRED

PACKING 629316 AS REQUIRED

PACKING 711614 AS REQUIRED

PACKING M83248-1-038 AS REQUIRED

PACKING MS29513-146 AS REQUIRED

PACKING MS9020-20 AS REQUIRED

PACKING MS9021-214 AS REQUIRED

PACKING MS9021-218 AS REQUIRED

Tool No. Tool Name Figure/Paragraph No.

Nomenclature Part No Quantity

Page 2 of 26DISTRIBUTION STATEMENT "D" Chg. Date: 15 JUNE 2016 Rev: 5

ILLUSTRATED SUPPORT EQUIPMENT

Figure T1. PWA 16471 Fixture

Figure T2. PWA 16478 Adapter

Figure T3. PWA 16506 Wrench

Figure T4. PWA 16507 Wrench

Figure T5. PWA 17700 Puller

Figure T6. PWA 43351

1 INTRODUCTION.

This Work Package contains instructions for fuel coolant oil cooler assembly depot maintenance. Part numbers and engine applicability are as follows:

PACKING MS9288-029 AS REQUIRED

PACKING MS9387-08 AS REQUIRED

PACKING MS9388-216 AS REQUIRED

PACKING ST1050-214 AS REQUIRED

For rework and reidentification of fuel oil cooler assembly valve housing, liner and thermostat replacement, refer to T.O. 2J-TF33-53-2, SWP 019 01.

Part No.

P-3

P-5 P-7A P-9 P-11A PW-100A

PW-102

PW-103 PW-102C

404900 X 428940 X X 463917 X X 467731 X X 467732 X 481603 X 481605 X 481606 X 482490 X 503343 X 503363 X 537944 X 537946 X 622259 X 715446 X

Page 3 of 26DISTRIBUTION STATEMENT "D" Chg. Date: 15 JUNE 2016 Rev: 5

2 FUEL COOLANT OIL COOLER ASSEMBLY - DISASSEMBLY (EXCEPT PN 715446 AND

801380).

(See Figure 1 through Figure 4.)

715558 X 733058 X 733386 X 745046 X 752956 X 794588 X 794589 X 794590 X 794591 X 794592 X 794593 X 801380 X

For rework and reidentification of PN 518756 housing assembly, and 524440 liner assembly, PN 367727 cover and PN 467732 or 481603 oil cooler assembly, refer to T.O. 2J-TF33-53-2 , SWP 019 01.

For rework and reidentification of fuel oil cooler assembly valve housing, liner and thermostat replacement, refer to T.O. 2J-TF33-

53-2, SWP 019 01.

a. Before disassembly, fuel coolant oil cooler assembly may be precleaned as follows:

(1) Plug all openings.

Super-chilled or heated parts can cause burns and/or frostbite.

Wear temperature resistant gloves when handling super-chilled or heated parts.

(2) Clean with high pressure wash with detergent and 135° to 155° F (57° to 68° C) hot water.

Page 4 of 26DISTRIBUTION STATEMENT "D" Chg. Date: 15 JUNE 2016 Rev: 5

14 FUEL COOLANT OIL COOLER ASSEMBLY (PN 404900, 467731, 467732, 481603, 524706,

622259, 733058, 733386, AND 752956) - TEST.

P/N 752956 with bypass valve installed - Refer to Paragraph 15 for bypass valve test. (See Figure 14.)

k. Torque plug(19) 800 to 900 pound-inches (Ref No. 1360). Lockwire plug.

l. Static pressure test complete assembly as specified in Paragraph 15. Lockwire bolts after successful test.

m. For valve body(27, Figure 5) incorporating drain hole, proceed as follows:

(1) Install lubricated packing on plug.

(2) Install plug in valve body.

(3) Torque plug and lockwire.

a. General requirements.

ENGINE OIL is combustible and is an irritant to skin, eyes, and respiratory system. Keep ignition sources away. Provide adequate ventilation. Minimize skin contact. Follow good hygiene practices. Wear protective clothing/equipment.

Spilled oil shall be wiped up immediately. Oil may soften painted surfaces and stain clothing.

(1) Lubricant shall be MIL-L-7808 engine oil.

CALIBRATING FLUID MIL-C-7024 is combustible and is an irritant to the skin, eyes, and respiratory system. Keep ignition sources away. Avoid direct body contact. Wear protective clothing/equipment. Provide adequate ventilation.

SOLVENT, DRY CLEANING, P-D-680, Type II or III, is combustible and is an irritant to skin, eyes, and respiratory system. Keep ignition sources away. Provide adequate ventilation. Wear protective clothing/equipment.

Page 21 of 26DISTRIBUTION STATEMENT "D" Chg. Date: 15 JUNE 2016 Rev: 5

15 FUEL COOLANT OIL COOLER ASSEMBLY - TEST.

(See Figure 15.)

(2) Calibrating test fluid shall be MIL-C-7024, Type II or petroleum solvent P-D-680.

(3) Oil inlet temperature shall be taken within three feet of cooler connections.

(4) Outlet temperature shall be taken within two feet of cooler outlet connections.

(5) Oil lines between measuring points and test unit should be insulated to minimize heat loss.

b. Test procedure.

(1) Static pressure test.

The temperature of cooler and of test fluid shall be the same within 15° F (8° C).

With no make up, there shall be no loss of pressure or visible leakage during 2 minute test period.

(a) Vent oil side to ambient pressure, and pressurize fuel side to 1190 to 1210 psig stabilized.

The temperature of cooler and test fluid shall be the same within 15° F (8° C).

With no make up, there shall be no loss of pressure or visible leakage during 2 minute test period.

(b) Vent fuel side to ambient pressure, and pressurize oil side to 195 to 205 psig stabilized.

Figure 14. Oil Regulator Bench Test Schematic

a. General requirements.

ENGINE OIL is combustible and is an irritant to skin, eyes, and respiratory system. Keep ignition sources away. Provide adequate ventilation. Minimize skin contact. Follow good hygiene practices. Wear protective clothing/equipment.

Page 22 of 26DISTRIBUTION STATEMENT "D" Chg. Date: 15 JUNE 2016 Rev: 5

CALIBRATING FLUID MIL-C-7024 is combustible and is an irritant to the skin, eyes, and respiratory system. Keep ignition sources away. Avoid direct body contact. Wear protective clothing/equipment. Provide adequate ventilation.

SOLVENT, DRY CLEANING, P-D-680, Type II or III, is combustible and is an irritant to skin, eyes, and respiratory system. Keep ignition sources away. Provide adequate ventilation. Wear protective clothing/equipment.

Spilled oil shall be wiped up immediately. Oil may soften painted surfaces and stain clothing.

(1) Lubricant shall be MIL-L-7808 engine oil.

(2) Calibrating test fluid shall be MIL-C-7024 Type II, or petroleum solvent P-D-680.

(3) Oil inlet temperature shall be taken within three feet of cooler connections.

(4) Outlet temperature shall be taken within two feet of cooler outlet connections.

(5) Oil lines between temperature measuring points and test unit should be insulated to minimize heat loss.

b. Instrumentation.

(1) Flowmeters to measure specified flows and to be read within ±1% accuracy. Flows shall also be set within ±1% of specified flow.

(2) Temperature measuring equipment capable of measuring specified temperatures within an accuracy of ±1° F (0.5° C). Test conditions shall be set within ±5° F (3° C) unless otherwise specified.

(3) Pressure gages capable of measuring specified pressures. Gages shall be set and read within ±1 psig.

(4) Oil flow bench capable of supplying flows up to 104 pounds per minute at 60 psig cooler pressure drop with an adjustable oil heater capable of maintaining 350° F (177° C) for a flow of 80 pounds per minute. Adjustable cooling of 4500 BTU for recirculated oil.

(5) Hydraulic (static) test bench pump, plumbing, fittings, etc., capable of 1800 psig.

c. Procedure.

(1) Thermostat tests.

(a) Torque valve 800 to 900 pound-inches. Ensure proper metal to metal contact is established

Page 23 of 26DISTRIBUTION STATEMENT "D" Chg. Date: 15 JUNE 2016 Rev: 5 between thermostat gasket and valve body boss.

(b) Install thermostat valve body assembly on PWA 16471 regulating valve fixture.

(c) Connect fixture to PWA 10675 stand using PWA 16478 regulating valve adapter.

(2) Thermostat open position test.

(a) Close oil-to-core bleed valve. Supply 10 to 20 psig oil to Oil In port at 150° to 160° F (60° to 71° C).

(b) Stabilize for 5 minutes.

(c) Ensure thermostat is open by observing continuous flow of oil through flowmeter at Oil Out port.

(3) Thermostat closed position test.

(a) Supply MIL-C-7024 test fluid at 210° to 220° F (99° to 104° C).

(b) Stabilize for 5 minutes.

Test fluid temperature may drop when pressure is reduced.

(c) Reduce pressure to approximately 10 to 20 psig. Open oil-to-core bleed valve. Ensure thermostat is closed.

(d) Drain line. Allow temperature to return to 200° F (93° C).

(e) Measure leakage. Leakage exceeding 150 cc per minute is unacceptable.

(4) Bypass valve test.

(a) With oil-to-core bleed valve closed, increase pressure to obtain a flow of 104 pounds per minute at 80° to 100° F (27° to 38° C).

(b) Test fluid shall start to flow at 35 to 40 psig minimum.

(c) Oil In pressure minus Oil Out pressure in excess of 65 psig is unacceptable.

(d) Determine pressure relief valve is in the closed position.

1 Install on flow bench. (See Figure 16.)

2 With No. 2 valve closed and No. 3 and No. 1 valves open, supply oil in port at 15 to 25 psig and 70° to 90° F (21° to 32° C). The pressure relief valve must remain fully closed.

Measure leakage through oil out port after draining line. Leakage must not exceed 150 cc per minute.

Page 24 of 26DISTRIBUTION STATEMENT "D" Chg. Date: 15 JUNE 2016 Rev: 5

16 PREPARATION FOR STORAGE.

(5) Static pressure tests.

Temperature of cooler and test fluid shall be the same within 15° F (8° C).

With no make up, there shall be no loss of pressure or visible leakage during 2 minute test period.

(a) Vent oil side to ambient pressure, and pressurize fuel side to 1190 to 1210 psig stabilized.

Temperature of cooler and test fluid shall be the same within 15° F (8° C).

With no make up, there shall be no loss of pressure or visible leakage during 2 minute test period.

(b) Vent fuel side to ambient pressure, and pressurize oil side to 195 to 205 psig stabilized.

Figure 15. Oil Regulator Bench Test Schematic

Figure 16. Oil Bypass Valve Test Pressure Relief Valve

a. If anticipated storage period is less than 21 days, no special preparation for storage is necessary.

b. If anticipated storage period is 21 days or more, proceed as follows:

(1) Drain any residual fluid from fuel and oil sections of cooler.

ENGINE OIL is combustible and is an irritant to skin, eyes, and respiratory system. Keep ignition sources away. Provide adequate ventilation. Minimize skin contact. Follow good hygiene practices. Wear protective clothing/equipment.

Page 25 of 26DISTRIBUTION STATEMENT "D" Chg. Date: 15 JUNE 2016 Rev: 5

MIL-L-7808 may be substituted for MIL-L-6081 oil for use in fuel side of cooler, but MIL-L-6081 oil shall not be permitted to contaminate MIL-L-7808 oil in oil side of cooler.

(2) Pour one pint of MIL-L-6081, Grade 1010 ten micron filtered oil into Fuel-In Port.

(3) Slosh oil around so that it covers all internal surfaces.

(4) Drain excess oil.

(5) Cap Fuel-In and Fuel-Out ports.

(6) Pour one pint of ten micron MIL-L-7808 filtered oil in Oil-In port.

(a) Slosh oil around so that it covers all internal surfaces.

(b) Drain excess oil.

(c) Cap Oil-In and Oil-Out ports.

SOLVENT, DRY CLEANING, P-D-680, Type II or III, is combustible and is an irritant to skin, eyes, and respiratory system. Keep ignition sources away. Provide adequate ventilation. Wear protective clothing/equipment.

c. Rinse all parts in P-D-680, Type II cleaning solvent.

Compressed air can generate flying debris and can cause severe injury if air blast penetrates the skin or eyes. Reduce compressed air pressure for cleaning or drying to less than 30 psig, and do not direct air blast toward other personnel.

d. Dry with clean compressed air.

Page 26 of 26DISTRIBUTION STATEMENT "D" Chg. Date: 15 JUNE 2016 Rev: 5