Fuel_Oil_Released_7J1-93-3.pdf

TO 7J1-93-3

TECHNICAL MANUAL

OVERHAUL INSTRUCTIONS

WITH ILLUSTRATED PARTS BREAKDOWN

FUEL-OIL COOLER ASSEMBLY

UA539800-1

UA539800-2

UNITED AIRCRAFT PRODUCTS, INC.

F33657-84-C-2014

GS-23F-0129L

Manual prepared by Edmond Scientific Company

This manual supersedes TO 7J1-93-3 dated 31 July 2002, including AFMC Form 252 Project Number

51MOCGBEAR6019R.

DISTRIBUTION STATEMENT - DISTRIBUTION AUTHORIZED TO THE DEPARTMENT OF DEFENSE AND US DOD CONTRACTORS ONLY, CRITICAL TECHNOLOGY, 31 JULY 2002. OTHER REQUESTS SHALL BE REFERRED

TO OC-ALC/LPFF (TOMA), TINKER AFB, OK 73145-3034.

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 - HANDLE IN COMPLIANCE WITH THE DISTRIBUTION STATEMENT AND DESTROY BY ANY METHOD THATWILL PREVENT DISCLOSURE OF THE CONTENTS OR RECONSTRUC-

TION OF THE DOCUMENT.

PUBLISHED UNDER AUTHORITY OF THE SECRETARY OF THE AIR FORCE

15 MARCH 2007

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 DESTROY SUPERSEDED PAGES.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 miniature pointing hands. Changes to wiring diagrams are indicated by shaded areas.

Dates of issue for original and changed pages are:

Original . . . 0 . . . . 15 March 2007

TOTAL NUMBER OF PAGES IN THIS PUBLICATION IS 46 CONSISTING OF THE FOLLOWING:

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

Title A i thru vi 1-1 thru 1-2 2-1 thru 2-3 2-4 Blank 3-1 3-2 Blank 4-1 4-2 Blank 5-1 thru 5-7 5-8 Blank 6-1

6-2 Blank 7-1 7-2 Blank 8-1 thru 8-5 8-6 Blank 9-1 9-2 Blank 10-1 thru 10-3 10-4 Blank 11-1 11-2 Blank 11-3 thru 11-4

*Zero in this column indicates an original page

A USAF

TABLE OF CONTENTS

Chapter Page

INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . iv

SAFETY SUMMARY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . v

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

1.1 PURPOSE OF EQUIPMENT . . . . . . . . . . . .1- 1

1.2 DESCRIPTION. (See Figure 1-1.) . . . . . . . .1- 1

1.2.1 Flow . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1- 1

1.2.2 Construction . . . . . . . . . . . . . . . . . . . . . . . . . . .1- 1

1.2.3 Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1- 1

1.3 OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . .1- 1

1.4 LEADING PARTICULARS. (See Table

1-1.) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1- 1

2 SPECIAL TOOLS AND TEST EQUIPMENT . . . .2- 1

2.1 GENERAL. (See Table 2-1.) . . . . . . . . . . . . .2- 1

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

3.1 GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . .3- 1

3.2 REMOVAL FROM PACKAGING. (See Figure

10-1.) . . . . . . . . . . . . . . . . . . . . . . . . . . . .3- 1

3.3 DISASSEMBLY. (See Figure 10-1.) . . . . . .3- 1

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

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

4.1.2 Cleaning Exterior Surfaces . . . . . . . . . . . . . .4- 1

4.1.3 Cleaning Internal Circuits . . . . . . . . . . . . . . .4- 1

5 INSPECTION, REPAIR, AND REPLACE-

MENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5- 1

5.1 INSPECTION. (See Figure 2-5, Figure 2-6, Figure 2-7, Figure 5-1 and Figure 10-1, and Table 5-1 and Table 5-2.) . . . . . . . .5- 1

5.1.1 Purpose . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5- 1

5.1.2 Areas of Inspection . . . . . . . . . . . . . . . . . . . . .5- 1

5.1.3 Types of Inspection . . . . . . . . . . . . . . . . . . . . .5- 1

5.1.4 Exterior Inspection . . . . . . . . . . . . . . . . . . . . .5- 1

5.2 REPAIR OF SCREW INSERTS, STUDS, AND

BUSHINGS. (See Figure 10-1.) . . . . .5- 1

5.3 REPAIR OF WELDED JOINTS. (See Figure

1, Figure 2-7, Figure 5-2 and Figure 10-1, and Table 5-2.) . . . . . . . . . . . . . . . . . . . .5- 3

5.3.1 General Requirements . . . . . . . . . . . . . . . . . .5- 3

5.3.2 Materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5- 3

5.3.3 Dents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5- 3

5.3.4 Gouges . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5- 3

Chapter Page

5.3.5 Minor Damage . . . . . . . . . . . . . . . . . . . . . . . . .5- 3

5.3.6 Scratches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5- 3

5.3.7 Welding Materials . . . . . . . . . . . . . . . . . . . . . .5- 3

5.3.8 Repair of Dents and Sharp Nicks or Distortion

in Shell Wall . . . . . . . . . . . . . . . . . . . . . .5- 3

5.3.9 Fuel and Oil Port Flanges . . . . . . . . . . . . . . .5- 4

5.3.10 Mounting Arms . . . . . . . . . . . . . . . . . . . . . . . .5- 4

5.3.11 Bushing Holes . . . . . . . . . . . . . . . . . . . . . . . . .5- 4

5.3.12 Damaged or Cracked Castings . . . . . . . . . . .5- 4

5.4 REPAIR OF BRAZED JOINTS. (See Figure

5-3 and Figure 10-1.) . . . . . . . . . . . . . . .5- 4

5.4.1 Joint Cracks not Extending Through Adjacent

Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5- 4

5.4.2 Joint Cracks Extending Into Adjacent

Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5- 5

5.5 REPLACEMENT. (See Figure 5-4, Figure 5-5

and Figure 10-1, and Table 5-2 and Table 5-3.) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5- 5

5.5.1 Screw Inserts . . . . . . . . . . . . . . . . . . . . . . . . . .5- 5

5.5.2 Studs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5- 5

5.5.3 Bushings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5- 5

5.5.4 Alternate (Field) Bushing Replacement . . .5- 5

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

7 ACCESSORIES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7- 1

8 TESTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8- 1

8.1 GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . .8- 1

8.2 TESTING. (See Figure 2-1, Figure 2-2, Figure

2-3, Figure 2-4, Figure 2-5, Figure 2-6, Figure 8-1, Figure 8-2, Figure 8-3 and Figure 8-4.) . . . . . . . . . . . . . . . . . . . . . . .8- 1

8.2.1 Internal Fuel Circuit Leak Test . . . . . . . . . . .8- 1

8.2.2 External Fuel Circuit Leak Test . . . . . . . . . .8- 1

8.2.3 Test Conditions . . . . . . . . . . . . . . . . . . . . . . . .8- 2

8.2.4 Test Parameters . . . . . . . . . . . . . . . . . . . . . . . .8- 2

8.2.5 Calibration of Test Instruments . . . . . . . . . . .8- 2

8.2.6 Test Fluids . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8- 2

8.2.7 Operation and Shutdown of PWA 50013 Test

Stand . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8- 2

8.2.8 Fuel Circuit Pressure Drop Test . . . . . . . . . .8- 3

8.2.9 Oil Circuit Pressure Drop Test . . . . . . . . . . .8- 4 i

TABLE OF CONTENTS - CONTINUED

Chapter Page

8.3 PRESERVATION AND PACKAGING. (See

Figure 10-1.) . . . . . . . . . . . . . . . . . . . . . .8- 5

8.3.1 Preservation . . . . . . . . . . . . . . . . . . . . . . . . . . .8- 5

8.3.2 Packaging . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8- 5

9 TABLE OF LIMITS . . . . . . . . . . . . . . . . . . . . . . . . . . . .9- 1

10 ILLUSTRATED PARTS BREAKDOWN . . . . . . . .9- 1

10.1 GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . .10- 1

10.2 ILLUSTRATED PARTS

BREAKDOWN . . . . . . . . . . . . . . . . . .10- 1

10.3 EXPLANATION OF COLUMNS USED

IN THE MAINTENANCE PARTS

LISTS . . . . . . . . . . . . . . . . . . . . . . . . . . .10- 1

Chapter Page

10.3.2 Figure and Index Number Column . . . . . .10- 1

10.3.4 Part Number Column . . . . . . . . . . . . . . . . . .10- 1

10.3.5 CAGE Column . . . . . . . . . . . . . . . . . . . . . . .10- 1

10.3.6 Description Column . . . . . . . . . . . . . . . . . . .10- 1

10.3.7 Units Per Assembly Column . . . . . . . . . . . .10- 1

10.3.8 Usable on Code Column . . . . . . . . . . . . . . .10- 1

10.3.9 SMR Code Column . . . . . . . . . . . . . . . . . . . .10- 1

11 DIFFERENCE DATA SHEETS . . . . . . . . . . . . . . . .11- 1

ii

LIST OF ILLUSTRATIONS

Number Title Page

Fuel-Oil Cooler Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. iv

1-1 Fuel-Oil Cooler Flow Diagram . . . . . . . . . . . . . . .1- 1

2-1 Fuel Outlet Tube Adapter . . . . . . . . . . . . . . . . . . . .2- 1

2-2 Fuel Inlet Tube Adapter . . . . . . . . . . . . . . . . . . . . .2- 1

2-3 Oil Inlet Tube Adapter . . . . . . . . . . . . . . . . . . . . . . .2- 2

2-4 Oil Outlet Tube Adapter . . . . . . . . . . . . . . . . . . . . .2- 2

2-5 Pressure Test Adapter (Fuel) . . . . . . . . . . . . . . . . .2- 2

2-6 Pressure Test Adapter (Oil) . . . . . . . . . . . . . . . . . .2- 2

2-7 Checking Fixture . . . . . . . . . . . . . . . . . . . . . . . . . . .2- 2

2-8 Pusher/Puller, Mount Bushing LM1116 . . . . . . . .2- 3

5-1 Types of Damage . . . . . . . . . . . . . . . . . . . . . . . . . . .5- 3

Number Title Page

5-2 Example of Welding Rod Ram . . . . . . . . . . . . . . .5- 4

5-3 Brazed Joint Section . . . . . . . . . . . . . . . . . . . . . . . .5- 5

5-4 Fuel-Oil Cooler — Bushing Removal . . . . . . . . .5- 6

5-5 Fuel-Oil Cooler — Bushing Installation . . . . . . .5- 6

8-1 Fuel Circuit Leak Test Schematic . . . . . . . . . . . . .8- 1

8-2 Fuel Circuit Pressure Drop Test Schematic . . . . .8- 3

8-3 Oil Circuit Pressure Drop Test Schematic . . . . . .8- 4

8-4 Oil Pressure Drop Limits . . . . . . . . . . . . . . . . . . . .8- 4

10-1 Fuel-Oil Cooler Assembly . . . . . . . . . . . . . . . . . .10- 2

11-1 Fuel-Oil Cooler Assembly . . . . . . . . . . . . . . . . . .11- 3

LIST OF TABLES

Number Title Page

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

2-1 Special Tools and Test Equipment List . . . . . . . .2- 1

5-1 Norml Inspection Data . . . . . . . . . . . . . . . . . . . . . .5- 1

Number Title Page

5-2 Bushing Dimensions . . . . . . . . . . . . . . . . . . . . . . . .5- 2

5-3 Fuel-Oil Cooler Mount Hole and Bushing Tolerances . . . . . . . . . . . . . . . . . . . . . . . .5- 6 iii

INTRODUCTION

PURPOSE. (See Figure 1.)

Thismanual contains overhaul instructions with Illustrated Parts Breakdown for the fuel-oil cooler, part numbers UA539800-1 and UA539800-2. The fuel-oil cooler, manufactured by United Aircraft Products Div., Parker Aerospace Group, Forest, Ohio 45843, is used on F100-PW-220, -220E, and -229 engine mod-els. See Figure 1 for typical configuration.

SCOPE

This manual presents information of value to depot maintenance personnel under the following headings:

Chapter 1. General Information. Data on the fuel-oil cooler; dimensions, leading particulars, and operating data.

Chapter 2. Special Tools and Test Equipment. Tabular data that lists special equipment required to repair the fuel-oil cooler.

Chapter 3. Disassembly. Procedures to remove fuel-oil cooler from packaging and disassembly.

Chapter 4. Cleaning. Procedures to clean the exterior surfaces and internal circuits of the fuel-oil cooler.

Chapter 5. Inspection. Repair and Replacement. Proce-dures to inspect, repair, and replace parts of the fuel-oil cooler.

Chapter 8. Testing. Procedures to leak and pressure test the fuel-oil cooler.

Chapter 10. Illustrated Parts Breakdown. Lists and describes all serviceable parts of the fuel-oil cooler.

Chapter 11. Difference Data Sheets.

Figure 1. Fuel-Oil Cooler Assembly.

TERMS

Throughout this manual the fuel-oil cooler assembly shall be referred to as the fuel-oil cooler.

ABBREVIATIONS

Symbols and abbreviations used in this manual are in accor-dance with ASMEY14.38, (supersedes MIL-STD-12) Abbrevi-ations for Use on Drawings and in Technical Type Publications.

Other symbols and abbreviations used in this manual are as fol-lows:

P Pressure SM&R Source, Maintenance, and Recoverabil-ity Delta Sigma psid pounds per square inch differential psig pounds per square inch gage pressure pph pounds per hour iv

SAFETY SUMMARY

INTRODUCTION

This technical order (T.O.) describes physical and chemical pro-cesses which may require the use of chemicals, solvents, paints or other commercially available hazardous material. This T.O.

also describes maintenance actions which may require handling or use of potentially dangerous parts or equipment.

Personnel performing maintenance procedures and practices included in this T.O. shall be familiar with safety precautions and procedures associated with chemicals and other hazardous materials, parts and equipment. The user of this T.O. shall consult their local safety and health staff and Material Safety Data Sheet (MSDS) concerning any questions on hazardous chemicals, personal protective equipment requirements, and appropriate handling and emergency procedures. The user shall become completely familiar with the manufacturer/supplier information and adhere to the procedures, recommendations, warnings, and cautions of the manufacturer/supplier for the safe use, handling, storage, and disposal of these materials.

Disregarding safety precautions and procedures or performing unauthorized maintenance can cause engine or equipment damage, serious injury, illness, or death.

BACKUP WRENCH

When torquing or breaking torque on any tube coupling nut, use a suitable wrench to apply torque to the fitting to which the part is attached. Failure to properly use a backup wrench can result in failure of tubes and accessories due to stress loading during torquing procedures.

BRAZING, SOLDERING AND WELDING

Brazing, soldering and welding operations may produce fumes that can be harmful to breathe. Arc welding emits ultraviolet light, which can burn the skin and eyes. Provide adequate ven-tilation. Wear protective clothing/equipment. Ensure gas bottles are properly secured.

CHEMICAL COMPOUNDS AND SOLUTIONS

Many of the chemical compounds and solutions used in clean-ing, inspection, and repair may cause irritation to the skin, eyes, and respiratory system. Many of the chemicals including their vapors may be poisonous, easily ignited, corrosive, and react violently with incompatible materials. Improper mixing and combining of these chemicals may produce violent reactions, rapid heat generation, and explosive/toxic gases. Heating cer-tain chemicals may cause toxic gases to be produced. Observe manufacturer’s warning labels and Material Safety Data Sheet (MSDS) instructions for proper handling, storage, and disposal.

Consult the local Safety Office for additional information.

COMPRESSED AIR

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. Use with effective chip guarding and personal protective equipment. Do not direct air blast toward other personnel.

COMPRESSED GASES

Many compressed gases are highly flammable/explosive and can cause suffocation at varied levels of concentration or expo-sure time. Some of the gases can freeze body tissue. Keep ignition sources away. Provide adequate ventilation. Wear pro-tective clothing/equipment. Store in properly marked/labeled containers at approved locations. Do not use in confined areas which may create an explosive atmosphere. Refer to specific Material Safety Data Sheet (MSDS) for additional information.

DANGEROUS PRESSURE

Pressure system precautions apply to all equipment using gases and fluids at all ranges of pressure. To avoid injury, stand clear of tooling and parts being pressure tested when pressure is being applied. Proper tool installation, shielding and hose connections shall be ensured before applying pressure. Ensure all system components are compatible with pressures applied and pressure medium used. Pressure shall be applied slowly.

ENGINE AND ACCESSORIES - TEMPERATURE

Aircraft engines and accessories are extremely hot following operation. Allow sufficient time to cool or wear protective clothing/equipment when maintenance or inspection tasks are required following engine operation. Failure to comply may result in injury to personnel.

ENGINE AND CONTROLS PRESERVATION

Engines and engine controls shall be drained of all fuel and pre-served before shipping. Failure to drain fuel can result in a fire hazard. Engine preservation replaces any fuel with oil, which acts as a corrosion preventing agent.

FOREIGN OBJECT DAMAGE (FOD)

Foreign objects can enter engine compartments and accessories during maintenance. Always be aware of the potential for for-eign object damage (FOD) entering any uncovered opening of an engine or accessory. Always thoroughly clean parts and com-partments to remove all foreign material. Make a final detail inspection of the work area when the job is finished. Follow standard operating procedures for tool and equipment account-ability.

FOOD AND TOBACCO

Wash hands and face thoroughly prior to smoking tobacco prod-ucts or eating food. Residue of the materials used in engine and equipment maintenance can cause serious health problems if ingested or inhaled in the smoke.

HEARING PROTECTION

The frequency and intensity of noise generated during some operations may cause an acute or chronic hearing impairment.

Wear approved hearing protection equipment. Contact the local safety office or bio-environmental engineering for further guid-ance.

v

HYDRAULIC TOOLING

Application of hydraulic pressure to tooling or engine parts can cause them to jump with enough force to cause personal injury. Excessive pressure applied to tooling by a hydraulic pump can cause a structural failure to the engine part and/or the tooling which could result in personal injury. Using a ram with a non-approved part number or exceeding hydraulic pump pressure can result in excessive pressure being applied to tool-ing. Do not exceed ram capacity for a given tool. Stand clear of tooling and engine parts during hydraulic tool operations.

JEWELRY

Remove rings, watches, necklaces, and other metallic objects that may be snagged or cause shock or burn hazards.

LIFTING, ROTATING, AND SUPPORTING

Personnel shall stay clear of objects being lifted during hoist operations or when objects are supported by temporary transi-tion supports. To prevent personal injury, use adequate number of personnel and appropriately rated lifting/handling devices to lift or move objects. Unless specified in the procedures, person-nel shall not work on objects suspended by a hoist or supported by temporary transition supports. Personnel shall be prepared for potential unbalanced conditions during hoist operations.

MAINTENANCE STANDS AND FIXTURES

Ensure modules or assemblies are firmly secured to work stands or fixtures before performingmaintenance procedures. Personal injury or damage to modules or assemblies may occur if a work stand or fixture slips.

METAL MACHINING PROCESSES

Metal machining processes may generate dust, fumes, filings, and/or shavings which may cause acute/chronic irritation to the skin, eyes, digestive tract, and respiratory system. Metallic dust vapors may form a fire hazard when exposed to heat, flame, or when in contact with oxidizing agents. Prior to performing any metal machining process, personnel shall consult their local safety and health staff and Material Safety Data Sheet (MSDS) to become familiar with the hazards and protective measures for a specific metal.

PACKING LUBRICATION (OIL AND FUEL SYSTEMS)

Use only the lubricant specified in the technical order to lubri-cate fuel and oil system packings. Use of an incompatible lubri-cant can cause oil foaming, clogging of critical fuel system fil-ters, and packing deterioration leading to leakage, possible fire and engine shutdown.

PROTECTIVE CLOSURES AND COVERS

Install protective closures on all plumbing and components immediately upon removal. Install protective covers on engine modules, assemblies, parts, and compartments when not being worked.

SUPER-CHILLED/HEATED PARTS AND EQUIPMENT

Super-chilled or heated parts and the equipment or agents used to heat or chill can cause burns, frostbite, or both. Wear temperature resistant gloves and other related protective clothing/equipment when handling chilled or heated parts or equipment. Super-chilled parts are fragile due to a lower resis-tance to impact. Heating parts beyond specified temperature limits can degrade heat treat qualities and result in part failure.

vi

CHAPTER 1

GENERAL INFORMATION

1.1 PURPOSE OF EQUIPMENT

1.1.1 The fuel-oil cooler controls the temperature of engine

oil for the F100-PW-220, -220E, and -229 engines, using fuel as the heat sink. Oil temperature is maintained below 350 F (177 C). Fuel temperature does not exceed 325 F (163 C).

1.2 DESCRIPTION. (See Figure 1-1.)

1.2.1 Flow The fuel-oil cooler utilizes a two-pass fuel

flow through tubes with multiple shell passes in the oil circuit. See Figure 1-1.

1.2.2 Construction The fuel circuit uses 0.125 inch diam-

eter tubes containing integrally formed turbulizers (beads).

Each tube is brazed to the headers and core baffles. The in and out oil ports are brazed to the core. The mounting arms and core are welded together.

1.2.3 Mounting A three point mounting system is used.

Each mounting arm contains a machined hole with a bushing pressed into the hole. The bushing helps prevent wear or dam-age to the machined hole.

1.3 OPERATION

1.3.1 Engine lubricating oil is circulated through the aircraft system and engine. Oil returns to the fuel-oil cooler where heat is transferred to the fuel circuit from the oil circuit.

1.4 LEADING PARTICULARS. (See Table 1-1.)

1.4.1 Refer to Table 1-1 for leading particulars of the fuel-oil cooler.

Figure 1-1. Fuel-Oil Cooler Flow Diagram

Table 1-1. Leading Particulars

Application F100 - PW-220, -220E, and -229 Engines

Heat Rejection 193,200 BTU/Hour

Weight 15 pounds maximum

Dimensions:

Length 15.37 inches

Width 6.50 inches

Height 7.0 inches

Fuel Circuit:

Table 1-1. Leading Particulars - Continued

Rate of Flow 4332 pph

Inlet Temperature 215 F (102 C)

Pressure Drop 35 psid max @ 13,400 pph @ 85 F ±5 F

(29 C ±3 C)

Proof Pressure 1500 +20/-0 psig

Fuel In Pad Per AS685-12 except threads are

0.250-28 UNJF-3B Per

MIL-S-8879

1-1

Table 1-1. Leading Particulars - Continued

Fuel Out Pad Per AS685-12, Stud Threads are

0.250-28 UNJF-3B

and 0.250-20 UNJC-3B per MIL-S-8879

Oil Circuit:

Rate of Flow 6660 pph

Inlet Temperature 325 F (163 C)

Pressure Drop 9-13.5 psid @ 6660 pph @ 325 F (163 C)

Table 1-1. Leading Particulars - Continued

Proof Pressure 375 +10/-0 psig

Oil In Pad Per AS685-16 except threads are

0.250-28 UNJF-3B Per

MIL-S-8879

Oil Out Pad Per AS685-16 except threads are

0.250-28 UNJF-3B Per

MIL-S-8879

1-2

CHAPTER 2

SPECIAL TOOLS AND TEST EQUIPMENT

2.1 GENERAL. (See Table 2-1.)

2.1.1 This chapter lists and illustrates all special tools and test equipment required for repair or testing of the fuel-oil cooler. Refer to Table 2-1 for all special tools and test equip-ment. Equivalent items may be used.

Table 2-1. Special Tools and Test Equipment List

Tool/Equipment Number

Figure Number

Nomenclature Use and Application

536048T201 Figure 2-1 Fuel Outlet Tube Adapter Paragraph 8.2., step c.

536048T202 Figure 2-2 Fuel Inlet Tube Adapter Paragraph 8.2., step b.

536048T203 Figure 2-3 Oil Inlet Tube Adapter Paragraph 8.2., step c.

536048T204 Figure 2-4 Oil Outlet Tube Adapter Paragraph 8.2., step b.

536048T205 Figure 2-5 Pressure Test Adapter (Fuel) Paragraphs 8.2, step a., step 8.2 b.

536048T206 Figure 2-6 Pressure Test Adapter (Oil) Paragraph 8.2, step c.

535950-3-T800 Figure 2-7 Checking Fixture Paragraph 5.1.4, step c., substep (6), Paragraph 5.3.10, step c.

LM1116 Figure 2-8 Pusher/Puller, Mount Bushing Paragraph 5.5.4.

PWA50013 Test Stand Paragraph 8.2.7.

PWA50018 Test Stand Paragraph 8.2.1.

Figure 2-1. Fuel Outlet Tube Adapter Figure 2-2. Fuel Inlet Tube Adapter

2-1

Figure 2-3. Oil Inlet Tube Adapter

Figure 2-4. Oil Outlet Tube Adapter

Figure 2-5. Pressure Test Adapter (Fuel)

Figure 2-6. Pressure Test Adapter (Oil)

Figure 2-7. Checking Fixture

2-2

Figure 2-8. Pusher/Puller, Mount Bushing LM1116

2-3/(2-4 blank)

CHAPTER 8

TESTING

8.1 GENERAL

8.1.1 The following tests must be performed on the fuel-

oil cooler after repair. This will ensure the fuel-oil cooler operates properly before installation on the engine.

8.2 TESTING. (See Figure 2-1, Figure 2-2, Figure 2-3, Figure 2-4, Figure 2-5, Figure 2-6, Figure 8-1, Figure 8-2, Figure 8-3 and Figure 8-4.)

NOTE

For operation and maintenance instructions covering PWA 50018 test stand, refer to T.O.

33D4-6-497-1.

8.2.1 Internal Fuel Circuit Leak Test Perform leak

test using PWA 50018 test stand. See Figure 8-1 for test schematic.

8.2.1.1 Test Setup

a. Install pressure test adapter (Figure 2-5) in fuel in port. Secure three AS9501-06 or equivalent (1/4-28 UNJF-3A x 1/2 inch long) hex head screws. Tighten screws to a torque of 50 to 60 inch-pounds.

b. Install pressure test adapter (Figure 2-5) in fuel out port. Secure three AN115857 or equivalent (1/4-20 UNJC-3A x 1/2 inch long) hex head screws. Tighten screws to a torque of 50 to 60 inch-pounds.

c. Cap fuel out pressure test adapter (Figure 2-5). Con-nect fuel in pressure test adapter to a source of com-pressed air or nitrogen.

d. Place fuel-oil cooler in water tank and rotate to remove all air from oil circuit.

8.2.1.2 Testing

a. Pressurize fuel circuit to 375 +10 -0 psig. This pres-sure shall be maintained throughout this test.

NOTE

If pressure can not be maintained be sure adapters or lines are not leak-ing.

b. Hold pressure for a minimum of one minute and observe fuel-oil cooler for air bubbles. There shall be no visible leakage or permanent deformation to fuel-oil cooler.

c. If there are any air bubbles go to step d. If there are no air bubbles go to step e.

d. Slowly rotate fuel-oil cooler, while observing bub-bles, to determine exact location of leak. Mark loca-tion.

e. Turn off compressed air and release pressure.

Remove fuel-oil cooler from water tank.

Figure 8-1. Fuel Circuit Leak Test Schematic

8.2.1.3 Post Test Procedures

a. Remove compressed air line from fuel in pressure test adapter (Figure 2-5). Remove cap from fuel out pressure test adapter.

b. Remove pressure test adapters (Figure 2-5) from fuel in and out ports.

c. Clean fuel-oil cooler per paragraph 4.1.2.

d. If air bubbles were present, repair fuel-oil cooler per paragraph 5.4. Repeat this test.

e. If no air bubbles were present, go to next test.

NOTE

For operation and maintenance instructions covering PWA 50018 test stand, refer to T.O.

33D4-6-497-1.

8.2.2 External Fuel Circuit Leak Test Perform leak test

using PWA 50018 test stand.

8-1

8.2.2.1 Test Setup

a. Install pressure test adapter (Figure 2-5) in fuel in port. Secure three AS9501-06 or equivalent (1/4-28 UNJF-3A x 1/2 inch long) hex head screws. Tighten screws to a torque of 50 to 60 inch-pounds.

b. Install pressure test adapter (Figure 2-5) in fuel out port. Secure three AN115857 or equivalent (1/4-20 UNJC-3A x 1/2 inch long) hex head screws. Tighten screws to a torque of 50 to 60 inch-pounds.

c. Install pressure test adapter (Figure 2-6), to fuel-oil cooler oil out port. Secure with three hex head screws, AS9501-06 or equivalent (1/4-28 UNJF-3A x 1/2 inch long). Tighten screws to a torque of 50 to 60 inch-pounds.

d. Install pressure test adapter (Figure 2-6), to fuel-oil cooler oil in port. Secure with three hex head screws, AS9501-06 or equivalent (1/4-28 UNJF-3A x 1/2 inch long). Tighten screws to a torque of 50 to 60 inch-pounds.

e. Cap fuel out pressure test adapter (Figure 2-5) and oil in and out pressure test adapters (Figure 2-6).

Connect fuel in pressure test adapter to a source of compressed air or nitrogen.

f. Place fuel-oil cooler in water tank

8.2.2.2 Testing

a. Pressurize fuel circuit to 375 +10 -0 psig. This pres-sure shall be maintained throughout this test.

NOTE

If pressure can not be maintained be sure adapters or lines are not leak-ing.

b. Hold pressure for a minimum of one minute and observe fuel-oil cooler for air bubbles. There shall be no visible leakage or permanent deformation to fuel-oil cooler.

c. If there are any air bubbles go to step d. If there are no air bubbles go to step e.

d. Slowly rotate fuel-oil cooler, while observing bub-bles, to determine exact location of leak. Mark loca-tion.

e. Turn off compressed air and release pressure.

Remove fuel-oil cooler from water tank.

8.2.2.3 Post Test Procedures

a. Remove compressed air line from fuel in pressure test adapter (Figure 2-5). Remove cap from fuel out pressure test adapter and oil in and out pressure test adapters.

b. Remove pressure test adapters (Figure 2-5) from fuel in and out ports.

c. Remove pressure test adapters (Figure 2-6) from oil in and out ports.

d. Clean fuel-oil cooler per paragraph 4.1.2.

e. If air bubbles were present repair fuel-oil cooler per paragraph 5.4. Repeat this test.

f. If no air bubbles were present, go to next test.

8.2.3 Test Conditions Unless otherwise specified, all

testing shall be performed under the following atmospheric conditions.

• Temperature - 77 F ±18 F (25 C ±10 C)

• Relative Humidity - Prevailing

• Barometric Pressure - 30" HgA ±2" Hg

8.2.4 Test Parameters Unless otherwise specified, all

testing shall be performed within the following maximum allowable tolerances.

• Temperature - ±5 F (±3 C)

• Pressure - ±3%

• Flow - ±3%

8.2.5 Calibration of Test Instruments All instruments

used for testing shall be calibrated and certified in accordance with MIL-C-45662, Calibration Systems Requirements.

8.2.6 Test Fluids The following fluids shall be used for

testing.

• Lubricating Oil per MIL-L-7808G

• Calibrating Fluid per MIL-C-7024, Type II

• Compressed air or nitrogen. Compressed air shall be dry and filtered.

8.2.7 Operation and Shutdown of PWA 50013 Test

Stand

WARNING

Failure to immediately push EMER- GENCY STOP valve (44, 45, or

565) when abnormally high, uncon-trollable temperature or pressure occurs during testing, may result in serious injury or death.

NOTE

For operational and mainte-nance instructions covering PWA 50013 test stand, refer to T.O.

33D4-6-487-1.

8.2.7.1 Operation

a. Connect test accessory to appropriate inlet and return fittings with hoses from kit (612). Connect pressure taps on tap blocks to fittings with appropri-ate range gages. Cap any unused fittings.

b. Pull out EMERGENCY STOP valves (44, 45, and

565) and depress test stand power ON pushbutton switch (E3). Pull out appropriate inlet circuit shutoff valve (75, 76, or 77).

c. Adjust temperature controllers (81, 82, and 83) to 85 F (29 C) set points.

8-2

d. Depress appropriate pump START push button.

NOTE

If fuel high pressure pump (503) operation is required, fuel low pres-sure pump (579) must be operating before high pressure pump (503) can be started. This also applies to oil high pressure pump (512) and oil low pressure pump (578).

e. Adjust circuit pressure controls to suit test require-ments.

f. Allow test fluid to circulate until temperature has stabilized at set point.

g. If this is first time test stand has been used in one week, operator should bleed filters, flow meters, and differential pressure gages while temperature is sta-bilizing.

8.2.7.2 Shutdown

a. Depress energized pump STOP pushbuttons on fuel and oil circuits as necessary.

b. Push in EMERGENCY STOP valve (44, 45, or

565).

c. Depress test stand power OFF pushbutton switch

(E3).

d. Turn off switch (E548) to completely de-energize test stand.

Figure 8-2. Fuel Circuit Pressure Drop Test Schematic

8.2.8 Fuel Circuit Pressure Drop Test See Figure 8-2

for test schematic.

8.2.8.1 Test Setup

a. Prepare test stand per paragraph 8.2.6.

b. Install fuel inlet tube adapter, 536048T202 (Figure

2-2), in fuel in port. Secure with three cap screws, AS9501-06 or equivalent, (1/4-28 UNJF-3A x 1/2 inch long). Tighten screws to a torque of 50 to 60 inch-pounds.

c. Install fuel outlet tube adapter tool, 536048T201 (Figure 2-1), in fuel in port. Secure with three hex head cap screws, (1/4-20 UNJC-3A x 1/2 inch long).

Tighten screws to a torque of 50 to 60 inch-pounds.

d. Connect fuel supply hose (78) to fuel inlet tube adapter (Figure 2-2).

e. Connect fuel return hose (79) to fuel outlet tube adapter (Figure 2-1).

f. Connect test stand gage (8) by connecting tap block

(58) with tap block (59) to fuel inlet and outlet tube adapters (Figure 2-1 and Figure 2-2) with appropri-ate hose connections as follows.

(1) Connect fuel inlet tube adapter (Figure 2-2) pressure tap (100) to tap block (58).

(2) Connect fuel outlet tube adapter (Figure 2-1) pressure tap (101) to tap block (58).

(3) Interconnect (87) tap block (59) to (106) tap block (58).

8.2.8.2 Testing

a. Turn on power (E3, E6, and E7).

b. Pull out test stand control valve (75) to flow cali-brating fluid through fuel-oil cooler.

c. Energize flowmeter, select channel 2.

d. Adjust test stand control valves (43) coarse adjust-ment and (85) fine adjustment to a flow rate of 13,400 pph ±3% pph. Set test stand temperature control (81) to read 80 to 90 F (27 to 32 C) on gage (48).

e. Record pressure drop from differential pressure gage (8). The pressure drop shall not exceed 35 psid ±5 psid with a 13,400 pph fuel flow at a temperature of 80 to 90 F (27 to 32 C).

f. Adjust control valve (85) until flowmeter reads 0;

then push in (75) to stop flow of calibrating fluid, MIL-C-7024, Type II, from test stand. Then turn off pump (12 and 13).

8.2.8.3 Post Test Procedures

a. Remove fuel-oil cooler from test set up.

b. Clean fuel-oil cooler per paragraph 4.1.2.

c. If pressure drop exceeds established limits clean the internal circuits per paragraph 4.1.3. Repeat this test.

If the fuel-oil cooler fails again it shall be replaced.

d. If pressure drop is within established limits go to next test.

8-3

8.2.9 Oil Circuit Pressure Drop Test See Figure 8-3 for

test schematic.

8.2.9.1 Test Setup

a. Prepare test stand per T.O. 33D4-6-487-1.

b. Connect oil outlet tube adapter tool, 536048T204

(Figure 2-4), to fuel-oil cooler oil out port. Secure with three hex head screws, AS9501-06 or equiv-alent (1/4-28 UNJF-3A x 1/2 inch long). Tighten screws to a torque of 50 to 60 inch-pounds.

c. Connect oil inlet tube adapter tool, 536048T203 (Figure 2-3), to fuel-oil cooler oil in port. Secure with three hex head screws, AS9501-06 or equiv-alent (1/4-28 UNJF-3A x 1/2 inch long). Tighten screws to a torque of 50 to 60 inch-pounds.

d. Connect oil supply hose (62) from test stand to oil inlet tube adapter (Figure 2-3).

(1) Connect oil inlet tube adapter (Figure 2-3) pres-sure tap (96) to tap block (58).

e. Connect oil return hose (63) from test stand to oil outlet tube adapter (Figure 2-4).

(1) Connect oil outlet tube adapter (Figure 2-4) pressure tap (97) to tap block (58).

8.2.9.2 Testing

a. Turn on power (E3, E4, E5).

b. Pull out test stand control valve (77) to flow lubri-cating oil through fuel-oil cooler.

c. Turn on flowmeter; select channel 3.

d. Adjust test stand control valves coarse adjustment

(42) and fine adjustment (84) to a flow rate of 6,660 pph ±3% pph. Set test stand temperature control (82) to read 80 to 90 F (27 to 32 C) on gage (49).

e. Record pressure drop from differential pressure gage (52) and actual temperature of oil on gage (116).

Figure 8-3. Oil Circuit Pressure Drop Test Schematic

Figure 8-4. Oil Pressure Drop Limits

8-4

f. Refer to Figure 8-4 to determine allowable pressure drop for an oil flow rate of 6,660 pph at the temper-ature recorded in step c. The recorded pressure drop shall not exceed this value ±5 psid.

g. If pressure drop exceeds established limits clean the internal circuits per paragraph 4.1.3. Repeat this test.

If the fuel-oil cooler fails again it shall be replaced.

h. Turn (42) to 0 on flowmeter.

i. Push control valve (77) to stop flow of lubricating oil from test stand. Then turn off pump (5 and 4).

8.2.9.3 Post Test Procedures

a. Remove fuel-oil cooler from test set up.

b. Drain excess oil from cooler.

c. Wipe excess oil from exterior of cooler.

8.3 PRESERVATION AND PACKAGING. (See Figure

10-1.)

8.3.1 Preservation

a. Clean and dry fuel-oil cooler per paragraph 4.1.2.

b. Install shipping plugs (1 and 2, Figure 10-1) or cover fuel and oil ports to prevent contamination of the fluid circuits.

8.3.2 Packaging

a. Wrap fuel-oil cooler in moisture barrier paper and place in sturdy cardboard carton. Only one fuel-oil cooler to a carton.

b. Tape carton closed.

c. Mark the part number and repair date on the outside of the carton.

8-5/(8-6 blank)

CHAPTER 9

TABLE OF LIMITS

9.1 INTENTIONALLY LEFT BLANK

9-1/(9-2 blank)

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