fuel_oil_Released_7J1-91-3.pdf

T.O. 7J1-91-3

TECHNICAL MANUAL

OVERHAUL INSTRUCTIONS

WITH

ILLUSTRATED PARTS BREAKDOWN

FUEL/OIL COOLER

(USED ON F110-GE-100 AND F118-GE-100 ENGINES)

PART NO. CONTROL DWG NO.

736597A 9338M23P02 736597B 9338M23P03 736597C 9338M23P04

(ATOS)

(Sundstrand)

(GE Aircraft Engines)

F33657-84-C-2011

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 February 2014. Refer other requests for this document to AFLCMC/LPSBBA, 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 JULY 2003 CHANGE 6 - 15 FEBRUARY 2014

BASIC AND ALL CHANGES HAVE BEEN

MERGED TO MAKE THIS A COMPLETE

PUBLICATION

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 DESTROY SUPERSEDED PAGES.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 July 2003 Change . . . . . . . . . . . . . . . . . . . . 1 . . . . . . . . . 1 December 2004 Change . . . . . . . . . . . . . . . . . . . . 2 . . . . . . . . . . . . . . 15 July 2005 Change . . . . . . . . . . . . . . . . . . . . 3 . . . . . . . . . . . . . 15 April 2011

Change . . . . . . . . . . . . . . . . . . . . 4 . . . . . . . . . . . . 1 August 2011 Change . . . . . . . . . . . . . . . . . . . . 5 . . . . . . . . . . 15 October 2011 Change . . . . . . . . . . . . . . . . . . . . 6 . . . . . . . . . 15 February 2014

TOTAL NUMBER OF PAGES IN THIS MANUAL IS 52, CONSISTING OF THE FOLLOWING:

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

Title A i - ii iii iv Blank v - vi 1-1 - 1-2 2-1 2-2 3-1 3-2 4-1 4-2 Blank 5-1 5-2 5-3 5-4 5-5 - 5-6 5-6.1 Added 5-6.2 Blank 6-1 6-2 6-3 6-4 Blank 7-1 - 7-3 7-4 7-5 - 7-7 7-8 7-9 7-10 - 7-14 8-1 - 8-2 9-1 - 9-4 9-5 9-6 A-1 Added A-2 Blank

*Zero in this column indicates an original page

A Change 6 USAF

TABLE OF CONTENTS

Chapter Page Chapter Page

INTRODUCTION.......................................................iii 5.1 General........................................................5-1

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

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

SAFETY SUMMARY.................................................v 5.4 Replacement.............................................5-6.1

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

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

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

1.1 Purpose........................................................1-1 6.2 Lubrication..................................................6-1

1.2 Description..................................................1-1 6.3 Assembly.....................................................6-1

1.3 Leading Particulars .....................................1-1 6.4 Assembly Inspection...................................6-3

2 SPECIAL TOOLS, TEST EQUIPMENT, 7 TESTING ..................................................................7-1

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

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

2.1 General........................................................2-1 7.2 Testing.........................................................7-1

2.2 Special Tools and Test Equip- 7.3 Troubleshooting ..........................................7-9 ment........................................................2-1 7.4 Preservation.................................................7-9

2.3 Consumable Materials ................................2-1

8 TABLE OF LIMITS.................................................8-1

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

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

3.1 General........................................................3-1 8.2 Torque Values.............................................8-1

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

3.3 Disassembly ................................................3-1 9 ILLUSTRATED PARTS BREAKDOWN...............9-1

4 CLEANING ..............................................................4-1 9.1 General........................................................9-1

9.2 Maintenance Parts List ...............................9-1

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

4.2 Cleaning ......................................................4-1 A UNIQUE IDENTIFICATION (UID) SUP-

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

5 INSPECTION, REPAIR, AND RE-

PLACEMENT ......................................................5-1 A.1 IUID Supplemental Information ...............A-1

LIST OF ILLUSTRATIONS

Number Title Page Number Title Page

1-1 Fuel/Oil Cooler ............................................... 1-2 6-3 X-Ray Inspection - Tube Bundle Inter- 1-2 Cooler Flow Diagram ..................................... 1-2 ference ........................................................ 6-3 2-1 Special Tools................................................... 2-2 7-1 Bypass Valve Test - Test Connections .......... 7-2 3-1 Matrix Removal .............................................. 3-2 7-2 Proof-pressure Test - Test Connections ......... 7-5 3-2 Valve Removal and Installation ..................... 3-2 7-3 Pressure-drop Test - Test Connections ........ 7-10 5-1 End Cover - Repair......................................... 5-4 7-4 Preservation - Test Connections................... 7-13 5-2 Matrix - Repair ............................................... 5-4 8-1 Limit - Locations ............................................ 8-2 5-3 Housing - Repair............................................. 5-5 9-1 Fuel/Oil Cooler - Exploded View .................. 9-4 5-4 Tubing Matrix - Sealing Matrix Tube 9-2 Shipping Parts - Exploded View.................... 9-6

Leaks........................................................... 5-6 A-1 IUID Identification Plate Location................ A-1 6-1 Preformed Packing - Installation.................... 6-2 6-2 Backup Rings and Preformed Packing -

Installation .................................................. 6-2

Change 4 i

LIST OF TABLES

Number Title Page Number Title Page

1-1 Leading Particulars ......................................... 1-1 5-1 Nondestructive Inspection - Fluores- 2-1 Special Tools and Test Equipment ................ 2-1 cent-Penetrant............................................. 5-3 2-2 Consumable Materials .................................... 2-1 7-1 Troubleshooting ............................................ 7-12 5-1 Inspection ........................................................ 5-2 A-1 Item Unique Identification (IUID) Re- 5-1 Inspection - Continued ................................... 5-3 quired Information .................................... A-1 ii Change 4

INTRODUCTION

Symbol Definition1. PURPOSE.

= Alternate

This technical manual provides information required for & And overhaul and testing of the fuel/oil cooler. The cooler is °F Degrees Fahrenheitmanufactured by Sundstrand Aviation, Unit of Sundstrand Corporation, 4747 Harrison Ave, PO Box 7002, Rockford,

4. LIST OF REFERENCED PUBLICATIONS.IL 61125-7002, for use on GE aircraft engines.

Referenced publications are as follows:2. SCOPE.

PublicationChapter 1 through Chapter 8 of this manual provide over- Number Titlehaul and test procedures, and Chapter 9 contains the IPB. A table of contents provides chapter, paragraph title, and page MCRL-1 USAF Master Cross-Reference number to help find information. A list of illustrations and List a list of tables provide the number, title, and page number TO 00-25-195 AF Technical Order System of illustrations and tables. Source, Maintenance, and Re-coverability Coding of Air

3. ABBREVIATIONS AND SYMBOLS. Force Weapons, Systems, and

Equipments Abbreviations and symbols used in this manual are in

TO 1-1-691 Aircraft Weapons Systemaccordance with MIL-STD-12, Abbreviations for Use on Cleaning and Corrosion ControlDrawings, and in Specifications, Standards, and Technical

TO 33B-1-1 Nondestructive Inspection Meth-Documents, except as follows:

ods

Abbreviation Definition TO 33D4-6-668-1 Lube Accessory Test Stand (AP) Attaching part TO 33D4-6-670-1 Fuel Accessory Test Stand Hg Mercury 1TL32-6670-1 Fuel Accessory Test Stand NSN National stock number TO 44H1-1-117 General Installation of Heli-Coil

InsertsPCR Publication change request

PPM Pounds per minute

PSID Pounds per square inch differential

SMR Source, maintenance, and recovera-bility

Change 3 iii/(iv blank)

TO 7J1-91-3

SAFETY SUMMARY

1. DEFINITIONS. 6. KEEP AWAY FROM LIVE CIRCUITS.

The following definitions apply to WARNINGS, CAU- Operating personnel shall think safety at all times. Do not TIONS, and NOTES found throughout this publication. replace components or make adjustments inside equipment with the electrical supply turned on. Under certain condi-tions, danger may exist even when power control is in the

WARNING OFF position due to charges retained by capacitors. To avoid injuries, always remove power, discharge, and ground a circuit before touching. Adhere to all lock out/tagAn operational or maintenance procedure, prac-out requirements.tice, condition, statement, etc., which if not strictly observed, could result in injury to or

7. RESUSCITATION.death of personnel.

Personnel working with or near dangerous voltage shall be trained in modern methods of resuscitation. InformationCAUTION and training sources may be obtained from Director of Base Medical Services.

An operational or maintenance procedure, prac-tice, condition, statement, etc., which if not 8. LUBRICATING OIL/FUEL.

strictly observed, could result in damage to or destruction of equipment or loss of mission Lubricating oil/fuel in liquid, vapor, or mist form is flam-effectiveness. mable, irritating to the skin and respiratory tract, and poisonous in the digestive tract. Remove saturated clothing, NOTE wash skin well, do not swallow liquid, and do not breathe mist and vapors.

An essential operational or maintenance proce-dure, condition, or statement which shall be 9. PERSONAL PROTECTIVE EQUIPMENT.

highlighted.

Wear protective clothing/equipment (gloves, apron, eye

2. GENERAL PRECAUTIONS. protection, etc.) approved for materials, procedures, and tools being used. Contact supervisor for guidance. If neces- The following are general safety precautions that are not sary, Bioenvironmental Engineer or Base Safety Office related to any specific procedure and therefore do not shall be contacted for guidance.

appear elsewhere in this publication. These are precautions that personnel shall understand and apply during the vari- 10. COMPRESSED AIR.

ous phases of equipment operation and maintenance.

Air pressure used in work area for cleaning or drying

3. DO NOT SERVICE OR ADJUST ALONE. operations shall be regulated to 30 PSI or less. Use approved safety equipment (goggles/face shield) to prevent Do not attempt internal service or adjustment of equipment injury to eyes. Do not direct jet of compressed air at self or unless another person capable of rendering aid and resusci- other personnel; or so that refuse is blown onto adjacent tation is present. work station. If additional air pressure is required to dislodge foreign materials from parts, ensure that approved

4. DO NOT WEAR JEWELRY. safety equipment is worn. Ensure air pressure is not detri-mental or damaging to the parts before applying high Remove rings, watches, and other metallic objects which pressured jets of air.

may cause shock or burn hazards.

5. FINGER RINGS.

Snagged finger rings have caused many serious injuries.

Unless specifically allowed by shop safety procedures, remove finger rings during all maintenance activity.

v visually determine if a part contains asbestos or cad-11. DANGEROUS PRESSURES.

mium, or if it is cadmium-plated, refer to the appropri-ate Illustrated Parts Breakdown to find these parts.Pressure system precautions apply to all ranges of pressure.

Before handling, replacing, or disposing of parts con-Care shall be taken during testing to ensure that all test taining asbestos or cadmium, ensure that all environ-connections are proper and tight before applying pressure mental controls are strictly followed.to the test setup; all system components shall be compatible

• Repairs: It is highly recommended that parts containingwith pressures applied. Personnel shall be protected by a asbestos or cadmium not be repaired. If, however,safety shield or located at a distance sufficient to prevent mechanical removal of material through grinding, buff-injury.

ing, drilling, or sanding is necessary, appropriate per-sonal protective equipment shall be used and national12. ASBESTOS/CADMIUM.

environmental controls shall be strictly complied with.

Ensure that Material Safety Data Sheets are availableThis engine component, and the support equipment called and followed for all of the materials used during anyout to maintain and repair it, may contain small amounts of process or operation.asbestos or cadmium. When working with this component, 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 cannot vi

CHAPTER 1

GENERAL INFORMATION

sealed to tube plate with expanded ferrules eliminating the1.1 PURPOSE.

need for welded or brazed joints. Warm engine oil enters the cooler and is directed over the matrix tubes in a singleThe purpose of the fuel/oil cooler is to cool engine oil.

pass. The oil is cooled by the transfer of heat to the relatively cool fuel passing through the matrix tubes. A1.2 DESCRIPTION.

flow diagram of the cooler is provided in Figure 1-2.

The cooler (Figure 1-1) is a shell-and-tube-type heat

1.3 LEADING PARTICULARS.exchanger that has a U-shaped tube matrix. Matrix tubes are supported at the open ends by a tube plate. Tube Leading particulars for the cooler are listed in Table 1-1.support is also provided by baffle plates, equally spaced along the length of matrix. Each tube is mechanically

Table 1-1. Leading Particulars

Characteristics Specifications Dimensions:

Overall length 12.880 inches maximum

Width 4.500 inches

Height 5.320 inches maximum

9338M23P02 and P03 weight (dry) 8.2 LB

9338M23P04 weight (dry) 8.6 LB

Matrix details:

Effective tube length 9.774 inches

Number of fuel passes One

Type of flow Counterflow

Average heat transfer 2680 BTU/minute

1-1

Figure 1-1. Fuel/Oil Cooler

Figure 1-2. Cooler Flow Diagram

1-2

CHAPTER 2

SPECIAL TOOLS, TEST EQUIPMENT, AND CONSUMABLE MATERIALS

2.1 GENERAL. 2.2 SPECIAL TOOLS AND TEST EQUIPMENT.

This chapter provides special tools, test equipment, and Special tools and test equipment required are listed in consumable materials required for fuel/oil cooler mainte- Table 2-1 and illustrated in Figure 2-1.

nance. Equivalent items may be used if the recommended tool, test equipment, or consumable material is not 2.3 CONSUMABLE MATERIALS.

available.

Consumable materials are listed in Table 2-2.

Table 2-1. Special Tools and Test Equipment

Figure 2-1 Part Number Index Number Nomenclature Use And Application

739093 (3C3392G01) Overhaul tool set, consisting of the following:

740433 (3C3392P02) 1 Assembly fixture Installation and removal of valve

740434 (3C3392P03) 2 Matrix puller Removal of matrix from hous-ing

742885 (3C3392P04) 3 Test block, oil bypass Testing of valve assembly

268687 Flushing stand Clean interior of body and tube assembly

3C3966 Lube accessory test stand Testing

3C3970 Fuel accessory test stand Testing

3C3970G05-OC001 Fuel accessory test stand Testing

GFE Micrometer, 3-4 inch Measuring

GFE Dial bore indicator, 4.0-6.4 inch Measuring

Table 2-2. Consumable Materials

Specification or Nomenclature Part Number CAGE General Use

Cloth, coated abrasive P-C-451, 800-grit Lapping

Cloth, cleaning CCC-C-46 Cleaning

Fluid, calibration MIL-C-7024, Type II Testing

Gloves, cotton MIL-G-3866 Repairing

Materials, chemical conversion MIL-C-81706, Class 1A, Repairing exposed aluminum surfaces Alodine 1200 or MIL-C-

Oil, lubricating MIL-L-6081, Grade 1010 Preserving

Change 3 2-1

Figure 3-1. Matrix Removal

Figure 3-2. Valve Removal and Installation

3-2

CHAPTER 7

TESTING

(2) Continually monitor external surfaces for leaks7.1 GENERAL.

during all tests.

This chapter provides procedures for testing, troubleshoot-

(3) The 3C3970 fuel accessory test stand can being, and preserving the fuel/oil cooler. The tests in this used to test the fuel section of the cooler.chapter are performed after assembly to ensure that the However, other fuel accessory test stands cancooler will operate satisfactorily. If the cooler fails to meet also be used.requirements of the applicable tests in this chapter, refer to troubleshooting table, then to Chapter 3 and Chapter 5 for (4) The 3C3966 lube accessory test stand can be applicable disassembly and repair procedures. After assem- used to test the oil section of the cooler. How-bly, perform the checkout test procedures in this chapter. ever, other lube accessory test stands can be All steps apply unless specified by part number. used.

7.2 TESTING. (5) If using 3C3970 fuel accessory test stand, 713ZA Pegasus controller shall be set to MODE

The following paragraphs provide procedures for perform- 2.

ing operational acceptance tests of the cooler. Refer to

b. Bypass Valve Testing. The following tests areTable 2-1 for a list of special tools and test equipment.

conducted using lubricating oil, MIL-L-7808, at an

a. Test Conditions and Test Setup. The following test inlet temperature of 50 to 110°F. All tests shall be conditions apply, unless otherwise specified: performed in sequence given.

NOTE

WARNING

Performing valve assembly (18, Figure 9-1) tests will determine serviceability of valve• Calibration fluid, MIL-C-7024, is flamma-assembly independent of oil cooler.ble and toxic to skin, eyes, and respiratory tract. Skin and eye protection is required.

(1) Perform operating pressure test (Figure 7-1) asUse in a well-ventilated area.

follows:

• Lubricating oil, MIL-L-7808, is toxic to

(a) Install preformed packing (22, Figure 9-1) onskin, eyes, and respiratory tract. Skin and valve assembly (18). Install valve assemblyeye protection is required. Avoid repeated or in 742885 oil bypass valve test block, usingprolonged contact. Use in a well-ventilated 740433 assembly fixture. Secure with retain-area.

ing ring (17).

(1) Perform all tests using calibration fluid, MIL-C-

(b) Install 742885 oil bypass valve test block,7024 Type II, or lubricating oil, MIL-L-7808.

with valve assembly (18) on 3C3966 lubeMaintain fluid temperature and room ambient accessory test stand. Connect oil inlet, oiltemperature at 70 to 90°F unless otherwise outlet, and pressure gage test stand connec-specified. Maintain barometric pressure of 24.0-tors to bypass valve test block.30.5 IN Hg.

7-1

Figure 7-1. Bypass Valve Test - Test Connections (Sheet 1 of 2)

7-2

Figure 7-1. Bypass Valve Test - Test Connections (Sheet 2)

7-3

(c) Press 733AA black pushbutton to turn on (e) Clean valve assembly (18) (Chapter 4).

hydraulic boost pump.

c. Proof-pressure Test. Maintain fluid temperature

(d) Select F* F110-100 SYSTEM TEST MENU and room ambient temperature of 60 100°F during on Micro-Flo 100. this test. Proceed as follows:

(e) Select A9* FUEL OIL COOLER TEST on (1) Connect cooler to the 3C3970 or 3C3970G05- Micro-Flo 100. OC001 fuel accessory text stand (Figure 7-2, sheet 1).

(f) Adjust lubricating oil flow through valve assembly (18) for a pressure drop between oil (2) Remove cap from OIL IN port and connect fluid inlet and oil outlet of 39.5-40.5 PSID, using supply line.

290CB regulator. Outlet flow shall not

(3) Turn 200CB valve to OPEN position.exceed 0.039 GPM or 150 cc/minute.

(4) Increase pressure to 500 PSIG, using 290DB(g) Slowly increase lubricating oil pressure until regulator.valve poppet cracks, using 290CB regulator.

This is indicated by a sudden flow increase

(5) Increase pressure to 10 PSIG, using 250FB(1 GPM or greater) as read on Micro-Flo regulator.100. The sudden flow increase shall occur at a differential pressure less than 47 PSID.

CAUTION(2) For full-flow Pressure Drop (Figure 7-1), adjust outlet flow to 9.70-10.00 GPM, using 290CB regulator. Pressure drop shall be 60 PSID Cooler shall be purged of all air. Air in cooler maximum. may result in unreliable readings.

(3) Perform poppet leakage test (Figure 7-1) as (6) Slowly apply pressure to OIL IN port and fill oil follows: circuit. Tilt and shake cooler to purge all air.

(a) Adjust lubricating oil inlet flow for a pres- (7) Decrease pressure to 0 PSIG, using 250FB sure drop of 36-40 PSID, using 290CB regu- regulator.

lator. Outlet flow shall not exceed 0.0396 GPM or 150 cc/minute. (8) Disconnect fluid supply line and install cap on

OIL IN port.

(b) Turn 290CB regulator CW to stop flow of lubricating oil to 742885 oil bypass valve test (9) Connect fluid supply line to FUEL IN port.

block. After oil has stopped flowing and inlet Ensure FUEL OUT cap is loose.

pressure has dropped, disconnect all test

(10) Loosen fitting on OIL OUT port and allow fluidstand connections to test block.

to leak off. The level of fluid in manometer shall

(c) Compress valve assembly (18, Figure 9-1), be approximately one-third full. Tighten fitting using 740433 assembly fixture. Remove and mark level of fluid in manometer.

retaining ring (17) from 742885 oil bypass

(11) Increase pressure to 10 PSIG, using 250FBvalve test block.

regulator. Allow fluid to flow through the fuel

(d) Remove 740433 assembly fixture and valve circuit until all air has been purged.

assembly (18) from 742885 oil bypass valve test block. Remove and discard preformed packing (22) from valve assembly.

7-4 Change 3

(15) Connect cooler to test stand (Figure 7-2, sheet 2).

WARNING

(16) Remove cap from FUEL IN port and connect fluid supply line.

Cooler shall be purged of all air before pressur-izing. Air remaining in cooler may have explo- (17) Increase pressure to 500 PSIG, using 290DB sive potential. Failure to purge air can result in regulator.

injury or death.

(18) Increase pressure to 10 PSIG, using 250FB

(12) Ensure all air has been purged. Tighten FUEL regulator.

OUT cap. Increase pressure to 2200 PSIG, using 290DB regulator.

CAUTION

(13) Increase pressure to 2070-2095 PSIG for 5 minutes minimum, using 250FB regulator.

Cooler shall be purged of all air. Air in coolerThere shall be no evidence of any external or may result in unreliable readings.internal leakage from cooler. There shall be no change in manometer displacement or distortion

(19) Slowly apply pressure to FUEL IN port and fillof cooler during the last minute of this test.

fuel circuit, using 290DB regulator. Tilt and shake cooler to purge all air.(14) Reduce pressure to 0 PSIG using 250FB and

290DB regulators, and disconnect test setup.

Figure 7-2. Proof-pressure Test - Test Connections (Sheet 1 of 3)

7-5

Figure 7-2. Proof-pressure Test - Test Connections (Sheet 2)

7-6

Figure 7-2. Proof-pressure Test - Test Connections (Sheet 3)

7-7

(20) Decrease pressure to 0 PSIG, using 250FB OUT ports. Pressure drop shall be 33 PSID regulator. maximum.

(21) Disconnect fluid supply line and install cap on (4) Stop fluid flow through fuel circuit. After flow FUEL IN port. Ensure OIL OUT cap is loose. is stopped and pressure is relieved, disconnect Connect fluid supply line to OIL IN port. supply and return lines.

(22) Loosen fitting on FUEL OUT port and allow (5) Connect test stand fluid supply line to cooler fluid to leak out. Level of fluid in manometer OIL IN port. Connect test stand fluid return line shall be about one-third full. Tighten fitting and to cooler OIL OUT port (Figure 7-3, sheet 2).

mark level of fluid in manometer.

(6) Pump fluid throughout cooler oil circuit.

(23) Increase pressure to 1,000 PSIG, using 290DB

(7) Increase fluid flow until pressure drop of 26-28regulator.

PSID is obtained across OIL IN and OIL OUT

(24) Increase pressure to 10 PSIG, using 250FB ports. Oil inlet flow shall be 134.5-160.5 PPM regulator. Allow fluid to flow through oil circuit

(8) Reduce pressure to 0 PSIG, using 250FB anduntil all air has been purged.

290DB regulators. Disconnect test setup.

e. Matrix Leak Test. Proceed as follows:WARNING

(1) Install preformed packing (12, Figure 9-1) on Serious injury can occur during pressure check matrix.

operations if air is not bled from system before proceeding to high pressure. Ensure air is bled

CAUTIONfrom lines and components at low pressure before applying high pressure.

Proper alignment of end cover pin (7) and slot(25) Ensure all air has been purged. Tighten OIL in matrix (13) is imperative. Misalignment mayOUT cap. Increase, and maintain for 5 minutes, result in leakage.OIL IN pressure to 750-775 PSIG, using 250FB regulator. There shall be no evidence of external (2) Attach matrix (13) on end cover (1), using two or internal leakage from cooler. There shall be modified bolts, part number 10606544-1, and no change in manometer displacement or distor- two nuts, part number 50085MRH84. Ensure tion of cooler during last minute of this test. proper alignment of cover pin (7) and slot in matrix.(26) Reduce pressure to 0 PSIG, using 250FB and 290DB regulators. Disconnect test setup. (3) Securely tighten the nuts.

d. Pressure-Drop Test. Proceed as follows (4) Attach local manufactured block-off plates to Figure 7-3): end cover FUEL OUT openings and the FUEL

IN opening.(1) Connect fuel accessory test stand fluid supply line to cooler FUEL IN port. Connect cooler (5) Attach one each local manufactured fuel-in FUEL IN port and test stand fluid return lines to adapter with its air inlet valve to the end cover.

cooler FUEL OUT port (Figure 7-3, sheet 1).

(6) Supply metered shop air, not to exceed 20 PSIG,

(2) Pump fluid through cooler fuel circuit. Open to adapter.

210CN and 210CP bleed valves and shake cooler until bubbles no longer appear.

(3) Increase fluid flow until 144.3-176.4 PPM is obtained across cooler FUEL IN and FUEL

7-8 Change 3

WARNING

• Drycleaning solvent, P-D-680, Type II, is flammable and toxic to skin, eyes, and respiratory tract. Skin, eye, and respiratory protection is required. Avoid repeated or prolonged contact.

• Calibration fluid, MIL-C-7024, is flamma-ble and toxic to skin, eyes, and respiratory tract. Skin and eye protection is required.

Use in a well-ventilated area.

CAUTION

Prolonged contact with water and/or solvents can cause corrosion. Water should be removed promptly from unit to prevent corrosion and additional leaks.

NOTE

Leak check can be conducted similarly using drycleaning solvent, P-D-680, calibration fluid, MIL-C-7024, or other approved fluids.

(7) Submerge matrix (13) in locally furnished water tank. Observe for quantity and location of air bubbles in tubes.

(8) Repair matrix tube (5.3 d).

7.3 TROUBLESHOOTING.

Table 7-1 lists troubles that may be encountered during testing, along with probable causes and suggested remedies.

7.4 PRESERVATION.

Preserve cooler as follows:

WARNING

Drycleaning solvent, P-D-680, Type II, is flam-mable and toxic to skin, eyes, and respiratory tract. Skin, eye, and respiratory protection is required. Avoid repeated or prolonged contact.

a. Flush cooler assembly with drycleaning solvent, P- D-680, Type II, to remove oil and other test fluids.

b. Dry cooler assembly, inside and out, remove all testing fluids. Cooler may be vacuum-dried.

c. Connect 3C3966 lube accessory test stand fluid supply line to the FUEL IN port (Figure 7-4, sheet 1).

d. Turn 263PA regulator to full CW position and 290CB regulator to full CW position.

WARNING

• Lubricating oil, MIL-L-7808, is toxic to skin, eyes, and respiratory tract. Skin and eye protection is required. Avoid repeated or prolonged contact. Use in a well-ventilated area.

• Lubricating oil, MIL-L-6081, is toxic to skin, eyes, and respiratory tract. Skin and eye protection is required. Avoid repeated or prolonged contact. Use in a well-ventilated area.

e. Apply 10 PSIG supply of lubricating oil, MIL-L- 6081 or MIL-L-7808, until fuel side of cooler is completely full, using valves 242GK and 242GE.

Lubricating oil shall be filtered to at least a 10 micron level.

f. Reduce pressure to 0 PSIG and remove fluid sup-ply line from the FUEL IN port and connect fluid supply line to the OIL IN port (Figure 7-4, sheet 2).

g. Apply 10 PSIG supply of lubricating oil until fuel side of cooler is completely full, using valves 242GK and 242GE. Lubricating oil shall be filtered to at least a 10 micron level.

h. Reduce pressure to 0 PSIG and disconnect fluid supply line.

i. Drain excess oil, install shipping parts (Figure 9-2), and tag unit to indicate lubricating oil used.

Change 6 7-9

Figure 7-3. Pressure-drop Test - Test Connections (Sheet 1 of 3)

7-10

Figure 7-3. Pressure-drop Test - Test Connections (Sheet 2)

7-11

Figure 7-3. Pressure-drop Test - Test Connections (Sheet 3)

Table 7-1. Troubleshooting

Trouble Probable cause Remedy Leakage Screws not properly torqued Torque screws

Damaged preformed packing or seals. Fail- Disassemble cooler and replace preformed packing or ure or leakage of matrix seals. Repair matrix ( 5.3d)

Low flow Restriction of fuel or oil passages Clean (4.2)

High flow Damaged or missing flow plate seals Replace flow plate seals

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Figure 7-4. Preservation - Test Connections (Sheet 1 of 2)

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Figure 7-4. Preservation - Test Connections (Sheet 2)

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