Fuel_Oil_Released_7J1-84-3.pdf

TO 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

(United Aircrafts Products) (GE Aircraft Engines) F33657-81-C-2006

THIS MANUAL SUPERSEDES TO 7J1-84-3, DATED 15 FEBRUARY 2016.

THIS MANUAL WAS TRANSFERRED TO A NEW EDITING SYSTEM. THE STYLE AND FORMAT WAS EXTENSIVELY CHANGED/RE-

VISED, THEREFORE, CHANGE BARS ARE OMITTED IN THIS RELEASE.

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 April 2017. Refer other requests for this document to AFLCMC/LPSLB, 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 APRIL 2017

Dates of issue for original and changed pages are:

Original. . . . . . . .0. . . . . . .15 April 2017

TOTAL NUMBER OF PAGES IN THIS PUBLICATION IS 42, CONSISTING OF THE FOLLOWING:

Page *Change No. No.

Page *Change No. No.

Page *Change No. No.

Title A i - iii iv Blank v vi Blank vii viii 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 - 7-7 7-8 Blank 8-1 - 8-9 8-10 Blank A-1 A-2 Blank

TO 7J1-84-3

LIST OF EFFECTIVE PAGES

INSERT LATEST CHANGED PAGES. DESTROY SUPERSEDED 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.

* Zero in this column indicates an original page.

A USAF

TABLE OF CONTENTS

Chapter Page

LIST OF ILLUSTRATIONS . . . . . . . . . . . . . iii

LIST OF TABLES . . . . . . . . . . . . . . . . . . . . iii

INTRODUCTION . . . . . . . . . . . . . . . . . . . . v

SAFETY SUMMARY . . . . . . . . . . . . . . . . . vii

1 GENERAL INFORMATION . . . . . . . . . . . . 1-1

1.1 Purpose and Description . . . . . . . . 1-1

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

2 SPECIAL TOOLS, TEST EQUIPMENT, AND

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

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

2.2 Consumable Materials . . . . . . . . . . 2-1

3 DISASSEMBLY. . . . . . . . . . . . . . . . . . . . . 3-1

3.1 General. . . . . . . . . . . . . . . . . . . . 3-1

3.2 Unpacking. . . . . . . . . . . . . . . . . . 3-1

3.3 Disassembly . . . . . . . . . . . . . . . . 3-1

4 CLEANING . . . . . . . . . . . . . . . . . . . . . . . 4-1

4.1 General. . . . . . . . . . . . . . . . . . . . 4-1

4.2 Cleaning . . . . . . . . . . . . . . . . . . . 4-1

5 INSPECTION, REPAIR, AND

REPLACEMENT . . . . . . . . . . . . . . . . . . 5-1

5.1 General. . . . . . . . . . . . . . . . . . . . 5-1

5.1.1 Item Unique Identification

(IUID) . . . . . . . . . . . . . . . . . . 5-1

5.2 Inspection . . . . . . . . . . . . . . . . . . 5-1

5.3 Repair . . . . . . . . . . . . . . . . . . . . 5-1

5.4 Replacement . . . . . . . . . . . . . . . . 5-1

6 ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . 6-1

6.1 General. . . . . . . . . . . . . . . . . . . . 6-1

6.2 Assembly . . . . . . . . . . . . . . . . . . 6-1

7 TESTING . . . . . . . . . . . . . . . . . . . . . . . . . 7-1

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

7.2 Testing . . . . . . . . . . . . . . . . . . . . 7-1

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

7.2.2 Bypass Valve Assembly

Testing . . . . . . . . . . . . . . . . . . 7-1

Chapter Page

7.2.3 Oil Circuit Pressure Drop Test . . . . 7-4

7.2.4 Fuel Circuit Pressure Drop Test . . . 7-5

7.2.5 Fuel Circuit Proof Pressure

Test . . . . . . . . . . . . . . . . . . . . 7-5

7.2.6 Oil Circuit Set-Up . . . . . . . . . . . . 7-5

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

7.3 Preservation. . . . . . . . . . . . . . . . . 7-6

8 ILLUSTRATED PARTS BREAKDOWN . . . . 8-1

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

8.1 General. . . . . . . . . . . . . . . . . . . . 8-1

8.2 Models Covered. . . . . . . . . . . . . . 8-1

8.3 Finding Part Numbers, Illustration, Description . . . . . . . . . . . . . . . 8-1

8.3.1 Maintenance Parts List . . . . . . . . . 8-1

8.3.2 Figure and Index Number

Column . . . . . . . . . . . . . . . . . 8-1

8.3.3 Part Number Column . . . . . . . . . . 8-1

8.3.3.1 Commercial Hardware . . . . . . . . . 8-1

8.3.3.2 Parts Not Illustrated . . . . . . . . . . . 8-1

8.3.3.3 Marking . . . . . . . . . . . . . . . . . . . 8-1

8.3.3.4 Government Furnished Equipment

(GFE) And Contractor Furnished Equipment (CFE) Covered by Separate Manuals . . . . . . . . . . . 8-2

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

8.3.5 Description Column . . . . . . . . . . . 8-2

8.3.5.1 Indentation . . . . . . . . . . . . . . . . . 8-2

8.3.5.2 Cross-Reference . . . . . . . . . . . . . . 8-2

8.3.6 Units Per Assembly Column . . . . . 8-2

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

8.3.8 Source, Maintenance, And Recover-

ability (SMR) Code Column . . . 8-3

8.3.9 Numerical Index . . . . . . . . . . . . . 8-3

8.3.9.1 Part Number Column . . . . . . . . . . 8-3

8.3.9.2 Figure and Index Number

Column . . . . . . . . . . . . . . . . . 8-3

8.3.10 Reference Designator Index . . . . . . 8-3

8.3.10.1 Reference Designator Column . . . . 8-3

8.3.10.2 Figure and Index Number

Column . . . . . . . . . . . . . . . . . 8-3

8.4 Repair Parts Kits . . . . . . . . . . . . . 8-3

8.5 Usable on Codes . . . . . . . . . . . . . 8-3

8.6 Source, Maintenance, and Recover-

ability (SMR) Codes. . . . . . . . . 8-3

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

8.8 Commercial And Government Entity

(CAGE) . . . . . . . . . . . . . . . . . 8-3

SECTION II MAINTENANCE PARTS

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

i

Chapter Page

APPENDIX A ITEM UNIQUE IDENTIFICA-

TION (IUID) SUPPORTING

INFORMATION. . . . . . . . . . . . . . . . . . . . A-1

Chapter Page

A.1 IUID Supplemental Information . . . . . . . . . . . . . . . A-1

TO 7J1-84-3

TABLE OF CONTENTS - CONTINUED

ii

LIST OF ILLUSTRATIONS

Number PageTitle

1-1 Fuel/Oil Cooler . . . . . . . . . . . . . . . . . . 1-2 7-1 Bypass Valve Test Connections to 3C3966

Test Stand . . . . . . . . . . . . . . . . . . . . 7-2 7-2 Oil Circuit Pressure Drop Test Connection to 3C3966 Test Stand . . . . . . . . . . . . 7-3 7-3 Oil Circuit Proof Pressure Test Connec-tions to 3C3970 Test Stand . . . . . . . . 7-3 7-4 Fuel Circuit Proof Pressure Test Connec-tion to 3C3970 Test Stand . . . . . . . . . 7-4

Number PageTitle

7-5 Fuel Circuit Pressure Drop Test Connec-tion to 3C3970 Test Stand . . . . . . . . . 7-6

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

8-1 Fuel/Oil Cooler - Exploded View . . . . . . 8-8 A-1 IUID Identification Plate Location. . . . . . A-1

LIST OF TABLES

Number PageTitle

1-1 Leading Particulars . . . . . . . . . . . . . . . . 1-1 2-1 Special Tools and Test Equipment . . . . . . 2-1 2-2 Consumable Materials . . . . . . . . . . . . . . 2-1 5-1 Inspection . . . . . . . . . . . . . . . . . . . . . . 5-1

Number PageTitle

5-2 Nondestructive Inspection - Fluorescent-penetrant . . . . . . . . . . . . 5-2

A-1 IUID Required Information . . . . . . . . . . A-1 iii/(iv blank)

INTRODUCTION

1 PURPOSE.

This technical manual provides information required to sup-port overhaul and testing of fuel/oil cooler. The cooler is manufactured by United Aircraft Products Inc, Dayton Inter-national Airport, Box 1355, Dayton, OH 45401. The cooler is used on General Electric F101-GE-102 engines.

2 SCOPE.

Chapter 1 through Chapter 7 of this manual contain overhaul and test procedures. Chapter 8 contains a parts breakdown for cooler. A table of contents indicates chapter, paragraph title, and page numbers to help find information. A list of illustrations and a list of tables indicate number, title, and page number of illustrations and tables provided.

3 SYMBOLS.

The following is an explanation of symbols used if appli-cable. All symbols used in this manual are in accordance with symbols per ASME Y14.38M.

- Not illustrated

* Requisition this marking in accordance with the requirements of DoDI 5330.03_AFI 33-

# Detail parts are listed in a separate manual = Alternate Part F Follows

4 ABBREVIATIONS.

All abbreviations used in this manual are in accordance with ASME Y14.38M for use on drawings, specifications, stan-dards, and in technical documents, except as follows:

AR As Required AP Attaching Parts IUID Item Unique Identification NHA Next Higher Assembly SMR Source, Maintenance, and Recoverability UII Unique Item Identifier UID Unique Identification

5 LIST OF RELATED PUBLICATIONS.

These publications contain information in support of this technical manual and are required to accomplish the pre-scribed maintenance:

List of Related Publications

Number Title TO 00-5-1 AF Technical Order System TO 00-25-260 Unique Identification Asset

Marking and Tracking

6 LIST OF APPLICABLE TIME COMPLIANCE

TECHNICAL ORDERS.

The following list of Time Compliance Technical Orders (TCTOs) affect the technical content of this manual. Only current TCTOs are listed. A TCTO is deleted from this list when rescinded, superseded, or fully incorporated.

List of Time Compliance Technical Orders

TCTO

Number

TCTO

Title

TCTO

Date

None applicable

7 IMPROVEMENT REPORTS.

Recommendations for improvements to this technical order will be submitted on AFTO Form 22, Publication Change

Request, in accordance with TO 00-5-1. Complete forms will be forwarded to AFLCMC/LPSLB, Tinker AFB, Oklahoma 73145-3031.

v/(vi blank)

SAFETY SUMMARY

1 GENERAL SAFETY INSTRUCTIONS.

This safety summary includes general safety precautions and instructions that must be understood and applied during op-eration and maintenance to ensure personnel safety and pro-tection of equipment. Prior to performing any task, the WARNINGs, CAUTIONs, and NOTEs included in that task shall be reviewed and understood.

2 WARNINGS, CAUTIONS, AND NOTES.

WARNINGs and CAUTIONs are used in this manual to highlight operating or maintenance procedures, practices, conditions, or statements considered essential to protection of personnel (WARNING) or equipment (CAUTION).

WARNINGs and CAUTIONs immediately precede the step or procedure to which they apply. WARNINGs and CAU- TIONs consist of four parts: a heading (WARNING, CAU- TION, or Icon), a statement of the hazard, minimum precau-tions, and possible result if disregarded. NOTEs are used in this manual to highlight operating or maintenance proce-dures, practices, conditions, or statements that are not essen-tial to protection of personnel or equipment. NOTEs may precede or follow the step or procedure, depending upon the information to be highlighted. The headings used and their definitions are as follows.

Highlights an essential operating or maintenance procedure, practice, condition, statement, etc., which if not strictly observed, could result in in-jury to, or death of, personnel or long-term health hazards.

Highlights an essential operating or maintenance procedure, practice, condition, statement, etc., which if not strictly observed, could result in dam-age to, or destruction of, equipment or loss of mis-sion effectiveness.

NOTE

Highlights an essential operating or maintenance procedure, condition, or statement.

3 SAFETY.

This publication is intended to provide safe procedures and processes for accomplishing the maintenance herein de-scribed. It is, therefore, important that the warnings of pos-sible personnel injury be thoroughly understood and ob-served by the users of this manual. Changes or additions deemed necessary for safety improvements should be sub-mitted through channels to the prime ALC in accordance with TO 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.

4 PROCESSING.

The overhaul methods and procedures described in this tech-nical manual are intended as normal overhaul practice. Any deviations from these procedures and sequencing must first be evaluated and approved by local cognizant authority and documented per TO 00-5-1 in order to ensure the deviations are consistent with standard engineering practices and will neither decrease the quality of the overhauled end item nor increase the possibility of physical injury to those who use them. However, torque limits, calibration limits, and other special values or limits shall be strictly adhered to.

5 GENERAL PRECAUTIONS.

ASBESTOS/CADMIUM. This engine and the support equip-ment called out to maintain and repair it, may contain small amounts of asbestos or cadmium. When working with this engine, the following precautions shall be rigidly adhered to:

• Parts: A limited number of parts, such as bolts, nuts, and fasteners are cadmium plated. Since you can not visually determine if a part contains asbestos or cadmium or if it is cadmium plated, refer to your Illustrated Parts Breakdown (IPB) (TO 2J-F101-4) to find these parts. Before handling, replacing or disposing of parts containing asbestos or cadmium, ensure all environmental controls are strictly fol-lowed.

• Repairs: It is highly recommended that parts con-taining asbestos or cadmium not be repaired. If, however, mechanical removal of material such as grinding, buffing, drilling and sanding is necessary, appropriate personal protective equipment and na-tional environmental controls must be strictly com-plied with. Ensure Material Safety Data Sheets are available and followed for all of the materials used during any process or operation.

vii/(viii blank)

CHAPTER 1

GENERAL INFORMATION

1.1 PURPOSE AND DESCRIPTION.

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

The cooler consists of a tube bundle, shell, and bypass valve.

Fuel flowing through the tube bundle cools oil flowing around the tubes.

1.2 LEADING PARTICULARS.

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.

No special tools are required for disassembly or assembly of fuel/oil cooler. Fixtures required for testing fuel/oil cooler are supplied as part of test stands. Table 2-1 lists special tools and test equipment that are provided. If listed equip-ment is not available, equivalent equipment may be used.

2.2 CONSUMABLE MATERIALS.

Table 2-2 lists consumable materials used during cooler overhaul.

Table 2-1. Special Tools and Test Equipment

Tool or Equipment Number

Figure Number Nomenclature Use and Application

3C3966 --- Lube accessory test stand Testing (Refer to TO 33D4-6-668-1)

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

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

268687 --- Flushing stand Cleaning 8511631 --- Adapter fitting Cleaning

--- 2-D Handheld Barcode Reader IUID

Table 2-2. Consumable Materials

Nomenclature Specification or CAGE General Use Part Number

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 Polyurethane Humiseal 1A120, 1A33 Coating Solvent, drycleaning MIL-PRF-680, Type II Cleaning Stone, Arkansas SS-S-736 Removing high metal Wire, safety MS20995C32 Safety-wiring parts

2-1/(2-2 blank)

CHAPTER 7

TESTING

7.1 GENERAL.

The tests in this chapter shall be performed before and after assembly to ensure that fuel/oil cooler will operate satisfac-torily. If bypass valve or cooler fails any tests in this chapter, refer to Chapter 3 and Chapter 5 for applicable disassembly and repair procedures. After assembly, repeat test procedures in this chapter.

7.2 TESTING.

The following paragraphs contain instructions for minimum operational performance tests of cooler. Paragraph 7.2.2 pro-vides information for testing the bypass valve assembly (Figure 8-1, 2). The remaining steps provide information for testing assembled fuel/oil cooler. Refer to Table 2-1 for test equipment listing.

7.2.1 Test Conditions and Test Setup.

Lubricating oil in liquid, vapor or mist form is flammable, irritating to the skin and respiratory system, and poisonous in digestive tract. Remove saturated clothing and wash skin well. Don’t swal-low liquid and don’t breathe mist and vapor.

a. Conduct all tests with MIL-C7024 calibration fluid and MIL-L-7808 oil. Maintain fluid temperature and room ambient temperature between 60° and 100°F. Maintain barometric pressure between 24 and 30.5 inches Hg.

b. Continually monitor external surfaces for leaks during all tests.

c. The 3C3970 fuel accessory test stand can be used to test fuel section of cooler. However, other fuel acces-sory test stands can also be used. Test stand 3C3970G05-OC001 may be used as an equivalent stand to 3C3970. Figure 7-3, Figure 7-4, and Figure 7-5 show test fittings and connections for testing fuel section of cooler on 3C3970 test stand. Refer to TO 33D4-6- 670-1 or Manual 1TL32- 6670-1 for identification of fittings, hoses, and test connection ports.

d. The 3C3966 lube accessory test stand can be used to test oil section of cooler. However, other lube acces-sory test stands can be used. Figure 7-1 and Figure 7-2 show test fittings and connections for testing oil sec-tion of cooler on 3C3966 test stand. Refer to TO 33134-6-668-1 for identification of fittings, hoses, and test connection ports.

e. The instructions throughout this chapter use significant item number (SIN) references that apply to applicable test stand.

7.2.2 Bypass Valve Assembly Testing. Test valve as fol-

lows:

a. Install bypass valve in 136138904 test fixture.

b. Connect lines to test fixture (Figure 7-1). Follow notes on Figure 7-1 for connecting line to oil- out port.

(1) Disconnect outlet port and measure leakage in graduated cylinder.

(2)

c. Perform cracking pressure test as follows:

(1) Place beaker 2803C under outlet.

(a) Press 733AA pump start button.

(b) Select E* F101 tests on Micro-Flo 100 com-puter.

(c) Select AB* Fuel Oil Cooler test on Micro Flo 100 computer. Open valves 539BN, 539BP, 242GE, and 263PA.

(2) Using regulator 290CB, smoothly increase oil pressure until valve poppet cracks open. This will be indicated by a sudden increase in flow (over 50cc per minute) at the oil-out port.

(3) Record (061LA) inlet pressure reading. Pressure must be 41-47 PSIG. If out-of-limits, replace pop-pet spring (Figure 8-1, 6).

(4) There must be no sign of valve chatter, and no pressure or flow oscillations.

d. Perform poppet leakage test as follows:

7-1

(1) Using regulator 290CB, set 061LA inlet pressure to a minimum of 47 PSIG. Slowly reduce inlet pressure to 36-40 PSIG.

(2) Using 2803C beaker, measure leakage at oil- out port. Leakage shall not exceed 150 cc per minute.

If leakage exceeds limits, check seat of bypass valve cage (11) and valve poppet (5). Replace damaged part.

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

7-2

(3) Using 290CB regulator, reduce inlet pressure to zero as read on Micro-Flo computer (061LA).

e. Perform full-flow pressure drop test as follows:

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

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

7-3

(1) Connect line to oil-out port of test fixture (Figure 7-1).

(2) Using 290CB regulator, increase inlet pressure to establish flow of 9.85±0.1 gpm.

(3) Record the pressure drop.

NOTE

Fixture pressure drop is obtained by using a plug (part of fixture) in the test fixture in place of the bypass valve.

(4) Establish same conditions as in Step e(2) and re-cord differential pressure. Once obtained, check monthly or as needed to ensure that there has been no change.

(5) Subtract fixture pressure drop recorded in Step e(4) from value recorded in Step e(3). This is the bypass valve pressure drop. Maximum pressure drop across bypass valve shall be 60 psid. Re-place poppet spring (Figure 8-1, 6) or damaged part if out-of-limits.

(6) Using 290CB regulator, decrease inlet pressure to zero. Close 539BN, 539BP, 539BE, 242GE and 263PA valves.

(7) Disconnect lines from test fixture.

(8) Remove bypass valve from test fixture. If valve passed all tests, package valve and return it to assembly.

7.2.3 Oil Circuit Pressure Drop Test. Proceed as follows:

a. Connect fittings and lines to cooler (Figure 7-2 ).

b. Select Menu A8*. Open 249LN, 249LP, 242GE, and 263PA valves.

c. Using 290CB regulator, increase inlet pressure to es-tablish 024AA gage minimum flow of 9.85 ±0.1 gpm.

d. Record differential pressure between oil-in and oil-out ports.

e. Using 290CB regulator, decrease inlet pressure to zero.

f. Disconnect lines from oil-in and oil-out ports and con-nect the lines together. Using 290CB regulator, increase inlet pressure to establish 024AA gage minimum flow of 9.85 ±0.1 gpm.

g. Record tare differential pressure. Once obtained, check monthly or as needed to ensure that there has been no change.

h. Using 290CB regulator, decrease inlet pressure to zero.

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

7-4

i. Turn 200CA valve to closed position to isolate cooler from the system. Maintain pressure for a minimum of 5 minutes.

j. Close 249LN, 249LP, 249GE, and 263PA valves.

k. Subtract pressure recorded in Step g from value re-corded in Step d. This is the oil circuit pressure drop.

The pressure drop shall not exceed 28 psid. If out-of-limits, check bypass valve and cooler weldment oil cir-cuit.

l. Remove lines and adapters from cooler ports.

7.2.4 Fuel Circuit Pressure Drop Test. Proceed as fol-

lows:

a. Connect fittings and lines to cooler (Figure 7-5 ).

b. Select Menu A1*. For 3C3970G05-OC001, select cor-responding test screen for the pressure drop test.

c. Using 242GC and 244AA valves, establish a flow through fuel circuit 534AB of 150 ±5 pounds per min-ute. Bleed air from lines using 210CN and 210CP valves.

d. Record differential pressure (539BP/539BQ) between FUEL-IN and FUEL-OUT ports. Pressure drop shall not exceed 28 psid. If out-of- limits, repeat fuel circuit cleaning.

e. Using 242GC and 244AA valves, decrease flow through fuel circuit to zero.

f. Disconnect lines from cooler. Prop cooler to minimize fluid loss.

g. Cap FUEL-OUT line with 2133C, and FUEL- IN line with 2103R, 2100X, and 2133N.

7.2.5 Fuel Circuit Proof Pressure Test. Proceed as fol-

lows:

a. Connect fittings and lines to cooler as shown in Figure 7-4.

NOTE

Cooler will be kept upright to minimize fluid loss.

b. Prop cooler so that liquid height gauge is upright. Fill gauge to 2 inch mark.

c. Pump pressurizing fluid through fuel circuit until bubbles no longer appear at cooler FUEL OUT ports.

Seal off cooler FUEL OUT ports.

d. Adjust 290DA and 250FA regulators to set 1650 +25-0 psi on 539BA. Turn 200CA valve to OPEN and hold pressure for 5 minutes.

e. There shall be no change in liquid height gage dis-placement or distortion of cooler during last minute of test.

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

g. Adjust 290DA regulator until tension is released. Ad-just 250FA regulator until pressure on 079KA drops to zero. Adjust 250FA regulator counterclockwise to re-lease.

h. Disconnect line and remove fittings from cooler.

i. Fully drain all fluid from both circuits of cooler.

7.2.6 Oil Circuit Set-Up.

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

b. Select Menu A1*. For 3C3970G05-OC001, select cor-responding test screen for proof pressure test.

c. 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 210CP valves.

d. Disconnect lines from cooler. Prop cooler to minimize fluid loss.

e. Cap oil-out line with 2133C, and oil-in with 2103R, 2100C, and 2133N.

7.2.7 Oil Circuit Proof Pressure Test. Proceed as fol-

lows:

NOTE

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

a. Connect fittings and lines to cooler and to test stand ports (Figure 7-3).

b. Prop cooler so that liquid height gauge is upright. Fill gauge to 2 inch mark.

c. Pump pressurizing fluid through fuel circuit until bubbles no longer appear at cooler FUEL OUT ports.

Seal off cooler FUEL OUT ports.

7-5

d. Adjust 290DA and 250FA regulators to set 750 + 25 - 0 psi on 539BA and hold pressure for 5 minutes.

e. There shall be no sign of leakage from oil circuit to fuel circuit. There shall be no change in liquid height gage displacement or distortion of cooler during last minute of test.

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

g. Adjust 290DA regulator until tension is released. Ad-just 250FA regulator until pressure on 079KA drops to zero. Adjust 250FA regulator counterclockwise to re-lease. Remove liquid height gauge and cap FUEL- OUT port with 2133C. Cap FUEL-IN line with 2103R, and 2133N.

h. Disconnect line from cooler.

7.3 PRESERVATION.

Preserve cooler for storage or shipping as follows:

MIL-PRF-680, Type II is flammable and irritating to the skin, eyes, and respiratory tract. Wear goggles and other protective clothing, as neces-sary. Use in a well-ventilated area or an approved cleaning cabinet, and keep away from heat, sparks, and open flame.

a. Flush cooler with MIL-PRF-680 solvent to remove test fluids.

b. Dry cooler, inside and out, to remove all flushing fluid.

Cooler may be vacuum dried.

Lubricating oil in liquid, vapor or mist form is flammable, irritating to skin and respiratory sys-tem, and poisonous in digestive tract. Remove saturated clothing and wash skin well. Don’t swal-low liquid and don’t breathe mist and vapor.

c. Put a small amount of MIL-L-7808 oil that has been filtered to 10-microns absolute in both circuits.

d. Drain excess oil, install shipping caps, and tag unit to indicate preservation oil used. There shall be no sign of leakage from fuel circuit to oil circuit.

e. If assembly is not to be returned to service immedi-ately, wrap in MIL-B-121 barrier paper and pack in a carton to protect it from damage.

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

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

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7.3 PRESERVATION

SECTION II MAINTENANCE PARTS LIST